# 1DC 192

URL: https://r2r.tech/products/sensors/1dc-192.md

## Documentation

**3D Model (STEP):** [Mounting Bracket for 1in or 25mm Extrusion for WPS, ODC and 1DC Sensors](http://r2r.tech/documentation/3d-models/mounting-bracket-1in-or-25mm-extrusion-wps-odc-and-1dc-sensors.md)

**Additional documentation:**
- [1DC 192](http://r2r.tech/documentation/3d-models/1dc-192.md)
- [1DC 192 xx-QD](http://r2r.tech/documentation/2d-drawings/1dc-192-xx-qd.md)
- [1DC Product Brochure](http://r2r.tech/documentation/brochures/1dc-product-brochure.md)
- [1DC Series: Product Data Sheet](http://r2r.tech/documentation/manuals/1dc-series-product-data-sheet.md)
- [EtherNet/IP EDS File for Roll-2-Roll® Communication Module](http://r2r.tech/documentation/support-files/ethernetip-eds-file-roll-2-rollr-communication-module.md)
- [Mounting Bracket for 1.5in or 40mm Extrusion for WPS, ODC and 1DC Sensors](http://r2r.tech/documentation/3d-models/mounting-bracket-15in-or-40mm-extrusion-wps-odc-and-1dc-sensors.md)
- [New Mounting Brackets for WPS, ODC and 1DC sensors - 1.5 in or 40 mm extrusion](http://r2r.tech/documentation/2d-drawings/new-mounting-brackets-wps-odc-and-1dc-sensors-15-or-40-mm-extrusion.md)
- [New Mounting Brackets for WPS, ODC and 1DC sensors - 1in or 25 mm extrusion](http://r2r.tech/documentation/2d-drawings/new-mounting-brackets-wps-odc-and-1dc-sensors-1in-or-25-mm-extrusion.md)
- [Register Map for 1DC Series Roll-2-Roll® Sensor (v 4.3a+)](http://r2r.tech/documentation/manuals/register-map-1dc-series-roll-2-rollr-sensor-v-43a.md)
- [Rockwell/AB Add-on Instructions for 1DC Series of Roll-2-Roll® Sensor](http://r2r.tech/documentation/support-files/rockwellab-add-instructions-1dc-series-roll-2-rollr-sensor.md)
- [Roll-2-Roll® Control Center Pro Software (Windows)](http://r2r.tech/documentation/software/roll-2-rollr-control-center-pro-software-windows.md)
- [Sensor Installation Recommendations: Inspection Applications](http://r2r.tech/documentation/manuals/sensor-installation-recommendations-inspection-applications.md)

---

# 1DC 288

URL: https://r2r.tech/products/sensors/1dc-288.md

## Documentation

**3D Model (STEP):** [Mounting Bracket for 1in or 25mm Extrusion for WPS, ODC and 1DC Sensors](http://r2r.tech/documentation/3d-models/mounting-bracket-1in-or-25mm-extrusion-wps-odc-and-1dc-sensors.md)

**Additional documentation:**
- [1DC 288-xx](http://r2r.tech/documentation/3d-models/1dc-288-xx.md)
- [1DC 288-xx QD](http://r2r.tech/documentation/2d-drawings/1dc-288-xx-qd.md)
- [1DC Product Brochure](http://r2r.tech/documentation/brochures/1dc-product-brochure.md)
- [1DC Series: Product Data Sheet](http://r2r.tech/documentation/manuals/1dc-series-product-data-sheet.md)
- [EtherNet/IP EDS File for Roll-2-Roll® Communication Module](http://r2r.tech/documentation/support-files/ethernetip-eds-file-roll-2-rollr-communication-module.md)
- [Mounting Bracket for 1.5in or 40mm Extrusion for WPS, ODC and 1DC Sensors](http://r2r.tech/documentation/3d-models/mounting-bracket-15in-or-40mm-extrusion-wps-odc-and-1dc-sensors.md)
- [New Mounting Brackets for WPS, ODC and 1DC sensors - 1.5 in or 40 mm extrusion](http://r2r.tech/documentation/2d-drawings/new-mounting-brackets-wps-odc-and-1dc-sensors-15-or-40-mm-extrusion.md)
- [New Mounting Brackets for WPS, ODC and 1DC sensors - 1in or 25 mm extrusion](http://r2r.tech/documentation/2d-drawings/new-mounting-brackets-wps-odc-and-1dc-sensors-1in-or-25-mm-extrusion.md)
- [Register Map for 1DC Series Roll-2-Roll® Sensor (v 4.3a+)](http://r2r.tech/documentation/manuals/register-map-1dc-series-roll-2-rollr-sensor-v-43a.md)
- [Rockwell/AB Add-on Instructions for 1DC Series of Roll-2-Roll® Sensor](http://r2r.tech/documentation/support-files/rockwellab-add-instructions-1dc-series-roll-2-rollr-sensor.md)
- [Roll-2-Roll® Control Center Pro Software (Windows)](http://r2r.tech/documentation/software/roll-2-rollr-control-center-pro-software-windows.md)
- [Sensor Installation Recommendations: Inspection Applications](http://r2r.tech/documentation/manuals/sensor-installation-recommendations-inspection-applications.md)

---

# 1DC 384

URL: https://r2r.tech/products/sensors/1dc-384.md

## Documentation

**3D Model (STEP):** [Mounting Bracket for 1in or 25mm Extrusion for WPS, ODC and 1DC Sensors](http://r2r.tech/documentation/3d-models/mounting-bracket-1in-or-25mm-extrusion-wps-odc-and-1dc-sensors.md)

**Additional documentation:**
- [1DC 384](http://r2r.tech/documentation/3d-models/1dc-384.md)
- [1DC 384-xx QD](http://r2r.tech/documentation/2d-drawings/1dc-384-xx-qd.md)
- [1DC Product Brochure](http://r2r.tech/documentation/brochures/1dc-product-brochure.md)
- [1DC Series: Product Data Sheet](http://r2r.tech/documentation/manuals/1dc-series-product-data-sheet.md)
- [EtherNet/IP EDS File for Roll-2-Roll® Communication Module](http://r2r.tech/documentation/support-files/ethernetip-eds-file-roll-2-rollr-communication-module.md)
- [Mounting Bracket for 1.5in or 40mm Extrusion for WPS, ODC and 1DC Sensors](http://r2r.tech/documentation/3d-models/mounting-bracket-15in-or-40mm-extrusion-wps-odc-and-1dc-sensors.md)
- [New Mounting Brackets for WPS, ODC and 1DC sensors - 1.5 in or 40 mm extrusion](http://r2r.tech/documentation/2d-drawings/new-mounting-brackets-wps-odc-and-1dc-sensors-15-or-40-mm-extrusion.md)
- [New Mounting Brackets for WPS, ODC and 1DC sensors - 1in or 25 mm extrusion](http://r2r.tech/documentation/2d-drawings/new-mounting-brackets-wps-odc-and-1dc-sensors-1in-or-25-mm-extrusion.md)
- [Register Map for 1DC Series Roll-2-Roll® Sensor (v 4.3a+)](http://r2r.tech/documentation/manuals/register-map-1dc-series-roll-2-rollr-sensor-v-43a.md)
- [Rockwell/AB Add-on Instructions for 1DC Series of Roll-2-Roll® Sensor](http://r2r.tech/documentation/support-files/rockwellab-add-instructions-1dc-series-roll-2-rollr-sensor.md)
- [Roll-2-Roll® Control Center Pro Software (Windows)](http://r2r.tech/documentation/software/roll-2-rollr-control-center-pro-software-windows.md)
- [Sensor Installation Recommendations: Inspection Applications](http://r2r.tech/documentation/manuals/sensor-installation-recommendations-inspection-applications.md)

---

# 1DC 480

URL: https://r2r.tech/products/sensors/1dc-480.md

## Documentation

**3D Model (STEP):** [Mounting Bracket for 1in or 25mm Extrusion for WPS, ODC and 1DC Sensors](http://r2r.tech/documentation/3d-models/mounting-bracket-1in-or-25mm-extrusion-wps-odc-and-1dc-sensors.md)

**Additional documentation:**
- [1DC 480](http://r2r.tech/documentation/3d-models/1dc-480.md)
- [1DC 480-xx QD](http://r2r.tech/documentation/2d-drawings/1dc-480-xx-qd.md)
- [1DC Product Brochure](http://r2r.tech/documentation/brochures/1dc-product-brochure.md)
- [1DC Series: Product Data Sheet](http://r2r.tech/documentation/manuals/1dc-series-product-data-sheet.md)
- [EtherNet/IP EDS File for Roll-2-Roll® Communication Module](http://r2r.tech/documentation/support-files/ethernetip-eds-file-roll-2-rollr-communication-module.md)
- [Mounting Bracket for 1.5in or 40mm Extrusion for WPS, ODC and 1DC Sensors](http://r2r.tech/documentation/3d-models/mounting-bracket-15in-or-40mm-extrusion-wps-odc-and-1dc-sensors.md)
- [New Mounting Brackets for WPS, ODC and 1DC sensors - 1.5 in or 40 mm extrusion](http://r2r.tech/documentation/2d-drawings/new-mounting-brackets-wps-odc-and-1dc-sensors-15-or-40-mm-extrusion.md)
- [New Mounting Brackets for WPS, ODC and 1DC sensors - 1in or 25 mm extrusion](http://r2r.tech/documentation/2d-drawings/new-mounting-brackets-wps-odc-and-1dc-sensors-1in-or-25-mm-extrusion.md)
- [Register Map for 1DC Series Roll-2-Roll® Sensor (v 4.3a+)](http://r2r.tech/documentation/manuals/register-map-1dc-series-roll-2-rollr-sensor-v-43a.md)
- [Rockwell/AB Add-on Instructions for 1DC Series of Roll-2-Roll® Sensor](http://r2r.tech/documentation/support-files/rockwellab-add-instructions-1dc-series-roll-2-rollr-sensor.md)
- [Roll-2-Roll® Control Center Pro Software (Windows)](http://r2r.tech/documentation/software/roll-2-rollr-control-center-pro-software-windows.md)
- [Sensor Installation Recommendations: Inspection Applications](http://r2r.tech/documentation/manuals/sensor-installation-recommendations-inspection-applications.md)

---

# 1DC 768

URL: https://r2r.tech/products/sensors/1dc-768.md

## Documentation

**3D Model (STEP):** [Mounting Bracket for 1in or 25mm Extrusion for WPS, ODC and 1DC Sensors](http://r2r.tech/documentation/3d-models/mounting-bracket-1in-or-25mm-extrusion-wps-odc-and-1dc-sensors.md)

**Additional documentation:**
- [1DC 768](http://r2r.tech/documentation/3d-models/1dc-768.md)
- [1DC 768-xx QD](http://r2r.tech/documentation/2d-drawings/1dc-768-xx-qd.md)
- [1DC Product Brochure](http://r2r.tech/documentation/brochures/1dc-product-brochure.md)
- [1DC Series: Product Data Sheet](http://r2r.tech/documentation/manuals/1dc-series-product-data-sheet.md)
- [EtherNet/IP EDS File for Roll-2-Roll® Communication Module](http://r2r.tech/documentation/support-files/ethernetip-eds-file-roll-2-rollr-communication-module.md)
- [Mounting Bracket for 1.5in or 40mm Extrusion for WPS, ODC and 1DC Sensors](http://r2r.tech/documentation/3d-models/mounting-bracket-15in-or-40mm-extrusion-wps-odc-and-1dc-sensors.md)
- [New Mounting Brackets for WPS, ODC and 1DC sensors - 1.5 in or 40 mm extrusion](http://r2r.tech/documentation/2d-drawings/new-mounting-brackets-wps-odc-and-1dc-sensors-15-or-40-mm-extrusion.md)
- [New Mounting Brackets for WPS, ODC and 1DC sensors - 1in or 25 mm extrusion](http://r2r.tech/documentation/2d-drawings/new-mounting-brackets-wps-odc-and-1dc-sensors-1in-or-25-mm-extrusion.md)
- [Register Map for 1DC Series Roll-2-Roll® Sensor (v 4.3a+)](http://r2r.tech/documentation/manuals/register-map-1dc-series-roll-2-rollr-sensor-v-43a.md)
- [Rockwell/AB Add-on Instructions for 1DC Series of Roll-2-Roll® Sensor](http://r2r.tech/documentation/support-files/rockwellab-add-instructions-1dc-series-roll-2-rollr-sensor.md)
- [Roll-2-Roll® Control Center Pro Software (Windows)](http://r2r.tech/documentation/software/roll-2-rollr-control-center-pro-software-windows.md)
- [Sensor Installation Recommendations: Inspection Applications](http://r2r.tech/documentation/manuals/sensor-installation-recommendations-inspection-applications.md)

---

# 1DC 96

URL: https://r2r.tech/products/sensors/1dc-96.md

## Documentation

**3D Model (STEP):** [Mounting Bracket for 1in or 25mm Extrusion for WPS, ODC and 1DC Sensors](http://r2r.tech/documentation/3d-models/mounting-bracket-1in-or-25mm-extrusion-wps-odc-and-1dc-sensors.md)

**Additional documentation:**
- [1DC 96](http://r2r.tech/documentation/3d-models/1dc-96.md)
- [1DC 96-xx QD](http://r2r.tech/documentation/2d-drawings/1dc-96-xx-qd.md)
- [1DC Product Brochure](http://r2r.tech/documentation/brochures/1dc-product-brochure.md)
- [1DC Series: Product Data Sheet](http://r2r.tech/documentation/manuals/1dc-series-product-data-sheet.md)
- [EtherNet/IP EDS File for Roll-2-Roll® Communication Module](http://r2r.tech/documentation/support-files/ethernetip-eds-file-roll-2-rollr-communication-module.md)
- [Mounting Bracket for 1.5in or 40mm Extrusion for WPS, ODC and 1DC Sensors](http://r2r.tech/documentation/3d-models/mounting-bracket-15in-or-40mm-extrusion-wps-odc-and-1dc-sensors.md)
- [New Mounting Brackets for WPS, ODC and 1DC sensors - 1.5 in or 40 mm extrusion](http://r2r.tech/documentation/2d-drawings/new-mounting-brackets-wps-odc-and-1dc-sensors-15-or-40-mm-extrusion.md)
- [New Mounting Brackets for WPS, ODC and 1DC sensors - 1in or 25 mm extrusion](http://r2r.tech/documentation/2d-drawings/new-mounting-brackets-wps-odc-and-1dc-sensors-1in-or-25-mm-extrusion.md)
- [Register Map for 1DC Series Roll-2-Roll® Sensor (v 4.3a+)](http://r2r.tech/documentation/manuals/register-map-1dc-series-roll-2-rollr-sensor-v-43a.md)
- [Rockwell/AB Add-on Instructions for 1DC Series of Roll-2-Roll® Sensor](http://r2r.tech/documentation/support-files/rockwellab-add-instructions-1dc-series-roll-2-rollr-sensor.md)
- [Roll-2-Roll® Control Center Pro Software (Windows)](http://r2r.tech/documentation/software/roll-2-rollr-control-center-pro-software-windows.md)
- [Sensor Installation Recommendations: Inspection Applications](http://r2r.tech/documentation/manuals/sensor-installation-recommendations-inspection-applications.md)

---

# 1DC 960

URL: https://r2r.tech/products/sensors/1dc-960.md

## Documentation

**3D Model (STEP):** [Mounting Bracket for 1in or 25mm Extrusion for WPS, ODC and 1DC Sensors](http://r2r.tech/documentation/3d-models/mounting-bracket-1in-or-25mm-extrusion-wps-odc-and-1dc-sensors.md)

**Additional documentation:**
- [1DC 960](http://r2r.tech/documentation/3d-models/1dc-960.md)
- [1DC 960-xx QD](http://r2r.tech/documentation/2d-drawings/1dc-960-xx-qd.md)
- [1DC Product Brochure](http://r2r.tech/documentation/brochures/1dc-product-brochure.md)
- [1DC Series: Product Data Sheet](http://r2r.tech/documentation/manuals/1dc-series-product-data-sheet.md)
- [EtherNet/IP EDS File for Roll-2-Roll® Communication Module](http://r2r.tech/documentation/support-files/ethernetip-eds-file-roll-2-rollr-communication-module.md)
- [Mounting Bracket for 1.5in or 40mm Extrusion for WPS, ODC and 1DC Sensors](http://r2r.tech/documentation/3d-models/mounting-bracket-15in-or-40mm-extrusion-wps-odc-and-1dc-sensors.md)
- [New Mounting Brackets for WPS, ODC and 1DC sensors - 1.5 in or 40 mm extrusion](http://r2r.tech/documentation/2d-drawings/new-mounting-brackets-wps-odc-and-1dc-sensors-15-or-40-mm-extrusion.md)
- [New Mounting Brackets for WPS, ODC and 1DC sensors - 1in or 25 mm extrusion](http://r2r.tech/documentation/2d-drawings/new-mounting-brackets-wps-odc-and-1dc-sensors-1in-or-25-mm-extrusion.md)
- [Register Map for 1DC Series Roll-2-Roll® Sensor (v 4.3a+)](http://r2r.tech/documentation/manuals/register-map-1dc-series-roll-2-rollr-sensor-v-43a.md)
- [Rockwell/AB Add-on Instructions for 1DC Series of Roll-2-Roll® Sensor](http://r2r.tech/documentation/support-files/rockwellab-add-instructions-1dc-series-roll-2-rollr-sensor.md)
- [Roll-2-Roll® Control Center Pro Software (Windows)](http://r2r.tech/documentation/software/roll-2-rollr-control-center-pro-software-windows.md)
- [Sensor Installation Recommendations: Inspection Applications](http://r2r.tech/documentation/manuals/sensor-installation-recommendations-inspection-applications.md)

---

# BLA Series

URL: https://r2r.tech/products/actuators/bla.md

## Documentation

**3D Model (STEP):** [BLA-015-0600-TG or BLA-030-0600-TG](http://r2r.tech/documentation/3d-models/bla-015-0600-tg-or-bla-030-0600-tg.md)

**Additional documentation:**
- [BLA-067-0600-TG](http://r2r.tech/documentation/2d-drawings/bla-067-0600-tg.md)
- [BLA-0xx-0600-TG 2D Drawing](http://r2r.tech/documentation/2d-drawings/bla-0xx-0600-tg-2d-drawing.md)
- [CASE STUDY - Pneumo-Hydraulic Web Guide Upgrade](http://r2r.tech/documentation/case-studies/case-study-pneumo-hydraulic-web-guide-upgrade.md)
- [CASE STUDY: Web Guide Upgrade Kit for Aging Web Guides](http://r2r.tech/documentation/case-studies/case-study-web-guide-upgrade-kit-aging-web-guides.md)
- [CASE STUDY: Web Guide Upgrade of Pneumo-hydraulic Web Guide for a Slitting Operation](http://r2r.tech/documentation/case-studies/case-study-web-guide-upgrade-pneumo-hydraulic-web-guide-slitting.md)
- [LHS-005-0125-LP: 2D Drawing (dxf)](http://r2r.tech/documentation/2d-drawings/lhs-005-0125-lp-2d-drawing-dxf.md)
- [LHS-005-0400-LP: 2D Drawing (dxf)](http://r2r.tech/documentation/2d-drawings/lhs-005-0400-lp-2d-drawing-dxf.md)
- [LHS-005-0xxx-LP: 2D Drawing (pdf)](http://r2r.tech/documentation/2d-drawings/lhs-005-0xxx-lp-2d-drawing-pdf.md)
- [LHS-015-0150-WG: 2D Drawing (pdf)](http://r2r.tech/documentation/2d-drawings/lhs-015-0150-wg-2d-drawing-pdf.md)
- [LHS-020-0xxx-RF: 2D Drawing (dxf)](http://r2r.tech/documentation/2d-drawings/lhs-020-0xxx-rf-2d-drawing-dxf.md)
- [LHS-020-0xxx-RF: 2D Drawing (pdf)](http://r2r.tech/documentation/2d-drawings/lhs-020-0xxx-rf-2d-drawing-pdf.md)
- [LHS-030-xxxx-RF: 2D Drawing (pdf)](http://r2r.tech/documentation/2d-drawings/lhs-030-xxxx-rf-2d-drawing-pdf.md)
- [Power Supply Regen Clamp Wiring](http://r2r.tech/documentation/wiring-diagrams/power-supply-regen-clamp-wiring.md)
- [RLA-050-0600-TG: 2D Drawing (pdf)](http://r2r.tech/documentation/2d-drawings/rla-050-0600-tg-2d-drawing-pdf.md)
- [Roll-2-Roll® Actuators Brochure](http://r2r.tech/documentation/brochures/roll-2-rollr-actuators-brochure.md)
- [Roll-2-Roll® Upgrade Kit: Product Brochure](http://r2r.tech/documentation/brochures/roll-2-rollr-upgrade-kit-product-brochure.md)
- [Roll-2-Roll® Web Guide Upgrade Kit Product Brochure](http://r2r.tech/documentation/brochures/roll-2-rollr-web-guide-upgrade-kit-product-brochure.md)
- [SCU5 MD Wiring with MC QD 1141/1140/1240 + Web Guide Actuator](http://r2r.tech/documentation/wiring-diagrams/scu5-md-wiring-mc-qd-114111401240-web-guide-actuator.md)
- [SCU5 MD Wiring with MC QD 1180/1181/1211/1230/1231/1260 + Regen Clamp + Unwind/Rewind Actuator](http://r2r.tech/documentation/wiring-diagrams/scu5-md-wiring-mc-qd-118011811211123012311260-regen-clamp.md)
- [SCU5 MD Wiring with MC QD 1180/1181/1211/1230/1231/1260 + Web Guide Actuator](http://r2r.tech/documentation/wiring-diagrams/scu5-md-wiring-mc-qd-118011811211123012311260-web-guide-actuator.md)
- [SCU6x MxD Wiring Diagram with Unwind/Rewind (Small Load)](http://r2r.tech/documentation/wiring-diagrams/scu6x-mxd-wiring-diagram-unwindrewind-small-load.md)
- [Servo Center Servo Installation](http://r2r.tech/documentation/manuals/servo-center-servo-installation.md)
- [Unwind/Rewind Guides Brochure](http://r2r.tech/documentation/brochures/unwindrewind-guides-brochure.md)
- [Unwind/Rewind Installation Checklist](http://r2r.tech/documentation/manuals/unwindrewind-installation-checklist.md)

---

# Compact Web Guiding Systems

URL: https://r2r.tech/products/web-guides/compact-web-guiding-systems.md

## Documentation


**Additional documentation:**
- [ARIS Compact Web Guiding System Product Manual (V2.2)](http://r2r.tech/documentation/manuals/aris-compact-web-guiding-system-product-manual-v22.md)
- [ARIS SCU5 EtherNet/IP Configuration Manual](http://r2r.tech/documentation/manuals/aris-scu5-ethernetip-configuration-manual.md)
- [CASE STUDY: Compact Web Guide with Ethernet Communication](http://r2r.tech/documentation/case-studies/case-study-compact-web-guide-ethernet-communication.md)
- [Case Study - Line Guiding Application](http://r2r.tech/documentation/case-studies/case-study-line-guiding-application.md)
- [Compact Web Guiding System Product Brochure](http://r2r.tech/documentation/brochures/compact-web-guiding-system-product-brochure.md)
- [Compact Web Guiding System Product Manual (V2.4)](http://r2r.tech/documentation/manuals/compact-web-guiding-system-product-manual-v24.md)
- [Contrast guiding performance of web guides](http://r2r.tech/documentation/white-papers/contrast-guiding-performance-web-guides.md)
- [Dimensional drawing of Compact Web Guiding System](http://r2r.tech/documentation/2d-drawings/dimensional-drawing-compact-web-guiding-system.md)
- [Installation of Displacement Guide](http://r2r.tech/documentation/manuals/installation-displacement-guide.md)
- [LHS-005-0125-LP: 2D Drawing (dxf)](http://r2r.tech/documentation/2d-drawings/lhs-005-0125-lp-2d-drawing-dxf.md)
- [LHS-005-0400-LP: 2D Drawing (dxf)](http://r2r.tech/documentation/2d-drawings/lhs-005-0400-lp-2d-drawing-dxf.md)
- [LHS-005-0xxx-LP: 2D Drawing (pdf)](http://r2r.tech/documentation/2d-drawings/lhs-005-0xxx-lp-2d-drawing-pdf.md)
- [Master/Slave Web Guiding System Installation](http://r2r.tech/documentation/manuals/masterslave-web-guiding-system-installation.md)
- [Motor Controller - MC QD 1140/1141/1240/1241: 2D Drawing](http://r2r.tech/documentation/2d-drawings/motor-controller-mc-qd-1140114112401241-2d-drawing.md)
- [Motor Controller - MC QD 1140/1141/1240/1241: 2D Drawing (DXF)](http://r2r.tech/documentation/2d-drawings/motor-controller-mc-qd-1140114112401241-2d-drawing-dxf.md)
- [Motor Driver MC QD 1140/1141/1161/1180/1181/1211/1230/1231/1240/1260](http://r2r.tech/documentation/manuals/motor-driver-mc-qd-1140114111611180118112111230123112401260.md)
- [Roll-2-Roll® Web Guides: Product Brochure](http://r2r.tech/documentation/brochures/roll-2-rollr-web-guides-product-brochure.md)
- [SCU5 Controller: 2D Drawing (DXF)](http://r2r.tech/documentation/2d-drawings/scu5-controller-2d-drawing-dxf.md)
- [SCU5 Controller: 2D Drawing (pdf)](http://r2r.tech/documentation/2d-drawings/scu5-controller-2d-drawing-pdf.md)
- [SCU5 M: Web Guide Controller Product and User Manual (V2.6)](http://r2r.tech/documentation/manuals/scu5-m-web-guide-controller-product-and-user-manual-v26.md)
- [SCU5 MD Wiring with ODC Sensor, MC QD 1140/1141/1240 with Web Guide](http://r2r.tech/documentation/wiring-diagrams/scu5-md-wiring-odc-sensor-mc-qd-114011411240-web-guide.md)
- [SCU5: Sensor and Web Guide Controller User Manual v3.3](http://r2r.tech/documentation/manuals/scu5-sensor-and-web-guide-controller-user-manual-v33.md)
- [SCU5: Sensor and Web Guide Controller User Manual v3.4](http://r2r.tech/documentation/manuals/scu5-sensor-and-web-guide-controller-user-manual-v34.md)
- [Standard Operating Procedure (SOP): Center Guiding Application (v2.x)](http://r2r.tech/documentation/manuals/standard-operating-procedure-sop-center-guiding-application-v2x.md)
- [Standard Operating Procedure (SOP): Edge Guiding Application (v2.x)](http://r2r.tech/documentation/manuals/standard-operating-procedure-sop-edge-guiding-application-v2x.md)
- [Standard Operating Procedure (SOP): Line Guiding Application](http://r2r.tech/documentation/manuals/standard-operating-procedure-sop-line-guiding-application.md)
- [Web Guide Installation Checklist](http://r2r.tech/documentation/manuals/web-guide-installation-checklist.md)
- [Web Guide: Disturbance Rejection Performance](http://r2r.tech/documentation/white-papers/web-guide-disturbance-rejection-performance.md)
- [Web Guides: Dynamic Performance with High Speed Actuator](http://r2r.tech/documentation/white-papers/web-guides-dynamic-performance-high-speed-actuator.md)
- [Web Guides: Frequency response of the guide mechanism](http://r2r.tech/documentation/white-papers/web-guides-frequency-response-guide-mechanism.md)
- [Web Guides: How to Quantify the Dynamic Performance?](http://r2r.tech/documentation/white-papers/web-guides-how-quantify-dynamic-performance.md)

---

# LHS Series

URL: https://r2r.tech/products/actuators/lhs.md

## Documentation

**3D Model (STEP):** [LHS-005-0400-LP](http://r2r.tech/documentation/3d-models/lhs-005-0400-lp.md)

**Additional documentation:**
- [LHS-020-0400-RF](http://r2r.tech/documentation/3d-models/lhs-020-0400-rf.md)
- [LHS-020-0400-TG](http://r2r.tech/documentation/3d-models/lhs-020-0400-tg.md)
- [LHS-020-0600-RF](http://r2r.tech/documentation/3d-models/lhs-020-0600-rf.md)
- [LHS-020-x400-TG](http://r2r.tech/documentation/2d-drawings/lhs-020-x400-tg.md)
- [LHS-030-xxxx-RF](http://r2r.tech/documentation/3d-models/lhs-030-xxxx-rf.md)

---

# Low Profile Web Guides

URL: https://r2r.tech/products/web-guides/low-profile-web-guides.md

## Documentation


**Additional documentation:**
- [ARIS SCU5 EtherNet/IP Configuration Manual](http://r2r.tech/documentation/manuals/aris-scu5-ethernetip-configuration-manual.md)
- [Contrast guiding performance of web guides](http://r2r.tech/documentation/white-papers/contrast-guiding-performance-web-guides.md)
- [Dimensional drawing of Low Profile Web Guide - U Pattern](http://r2r.tech/documentation/2d-drawings/dimensional-drawing-low-profile-web-guide-u-pattern.md)
- [Dimensional drawing of Low Profile Web Guide - Z Pattern](http://r2r.tech/documentation/2d-drawings/dimensional-drawing-low-profile-web-guide-z-pattern.md)
- [Installation of Displacement Guide](http://r2r.tech/documentation/manuals/installation-displacement-guide.md)
- [LHS-005-0125-LP: 2D Drawing (dxf)](http://r2r.tech/documentation/2d-drawings/lhs-005-0125-lp-2d-drawing-dxf.md)
- [LHS-005-0400-LP: 2D Drawing (dxf)](http://r2r.tech/documentation/2d-drawings/lhs-005-0400-lp-2d-drawing-dxf.md)
- [LHS-005-0xxx-LP: 2D Drawing (pdf)](http://r2r.tech/documentation/2d-drawings/lhs-005-0xxx-lp-2d-drawing-pdf.md)
- [Low Profile Web Guide Product Manual (V2.4)](http://r2r.tech/documentation/manuals/low-profile-web-guide-product-manual-v24.md)
- [Low Profile Web Guides Product Brochure](http://r2r.tech/documentation/brochures/low-profile-web-guides-product-brochure.md)
- [Master/Slave Web Guiding System Installation](http://r2r.tech/documentation/manuals/masterslave-web-guiding-system-installation.md)
- [Motor Controller - MC QD 1140/1141/1240/1241: 2D Drawing](http://r2r.tech/documentation/2d-drawings/motor-controller-mc-qd-1140114112401241-2d-drawing.md)
- [Motor Controller - MC QD 1140/1141/1240/1241: 2D Drawing (DXF)](http://r2r.tech/documentation/2d-drawings/motor-controller-mc-qd-1140114112401241-2d-drawing-dxf.md)
- [Motor Driver MC QD 1140/1141/1161/1180/1181/1211/1230/1231/1240/1260](http://r2r.tech/documentation/manuals/motor-driver-mc-qd-1140114111611180118112111230123112401260.md)
- [Roll-2-Roll® Web Guides: Product Brochure](http://r2r.tech/documentation/brochures/roll-2-rollr-web-guides-product-brochure.md)
- [SCU5 Controller: 2D Drawing (DXF)](http://r2r.tech/documentation/2d-drawings/scu5-controller-2d-drawing-dxf.md)
- [SCU5 Controller: 2D Drawing (pdf)](http://r2r.tech/documentation/2d-drawings/scu5-controller-2d-drawing-pdf.md)
- [SCU5 M: Web Guide Controller Product and User Manual (V2.6)](http://r2r.tech/documentation/manuals/scu5-m-web-guide-controller-product-and-user-manual-v26.md)
- [SCU5 MD Wiring with MC QD 1141/1140/1240 + Web Guide Actuator](http://r2r.tech/documentation/wiring-diagrams/scu5-md-wiring-mc-qd-114111401240-web-guide-actuator.md)
- [SCU5 MD Wiring with ODC Sensor, MC QD 1140/1141/1240 with Web Guide](http://r2r.tech/documentation/wiring-diagrams/scu5-md-wiring-odc-sensor-mc-qd-114011411240-web-guide.md)
- [SCU5: Sensor and Web Guide Controller User Manual v3.3](http://r2r.tech/documentation/manuals/scu5-sensor-and-web-guide-controller-user-manual-v33.md)
- [SCU5: Sensor and Web Guide Controller User Manual v3.4](http://r2r.tech/documentation/manuals/scu5-sensor-and-web-guide-controller-user-manual-v34.md)
- [Standard Operating Procedure (SOP): Edge Guiding Application (v2.x)](http://r2r.tech/documentation/manuals/standard-operating-procedure-sop-edge-guiding-application-v2x.md)
- [Standard Operating Procedure (SOP): Line Guiding Application](http://r2r.tech/documentation/manuals/standard-operating-procedure-sop-line-guiding-application.md)
- [Web Guide Installation Checklist](http://r2r.tech/documentation/manuals/web-guide-installation-checklist.md)
- [Web Guide: Disturbance Rejection Performance](http://r2r.tech/documentation/white-papers/web-guide-disturbance-rejection-performance.md)
- [Web Guides: Dynamic Performance with High Speed Actuator](http://r2r.tech/documentation/white-papers/web-guides-dynamic-performance-high-speed-actuator.md)
- [Web Guides: How to Quantify the Dynamic Performance?](http://r2r.tech/documentation/white-papers/web-guides-how-quantify-dynamic-performance.md)

---

# MC QD 1140/1141/1240/1241 2A Driver

URL: https://r2r.tech/products/motor-drivers/mc-qd-2a.md



---

# MC QD 1180/1181/1260 5.5A Driver

URL: https://r2r.tech/products/motor-drivers/mc-qd-118011811260-55a-driver.md



---

# ODC 192

URL: https://r2r.tech/products/sensors/odc-192.md

## Documentation

**3D Model (STEP):** [1in Mounting Bracket for WPS and ODC Sensors](http://r2r.tech/documentation/3d-models/1in-mounting-bracket-wps-and-odc-sensors.md)

**Additional documentation:**
- [1.5in Mounting Bracket for WPS and ODC Sensors](http://r2r.tech/documentation/3d-models/15in-mounting-bracket-wps-and-odc-sensors.md)
- [Mounting Bracket for 1.5in or 40mm Extrusion for WPS, ODC and 1DC Sensors](http://r2r.tech/documentation/3d-models/mounting-bracket-15in-or-40mm-extrusion-wps-odc-and-1dc-sensors.md)
- [Mounting Bracket for 1in or 25mm Extrusion for WPS, ODC and 1DC Sensors](http://r2r.tech/documentation/3d-models/mounting-bracket-1in-or-25mm-extrusion-wps-odc-and-1dc-sensors.md)
- [New Mounting Brackets for WPS, ODC and 1DC sensors - 1.5 in or 40 mm extrusion](http://r2r.tech/documentation/2d-drawings/new-mounting-brackets-wps-odc-and-1dc-sensors-15-or-40-mm-extrusion.md)
- [New Mounting Brackets for WPS, ODC and 1DC sensors - 1in or 25 mm extrusion](http://r2r.tech/documentation/2d-drawings/new-mounting-brackets-wps-odc-and-1dc-sensors-1in-or-25-mm-extrusion.md)
- [ODC 192 xx-QD](http://r2r.tech/documentation/2d-drawings/odc-192-xx-qd.md)
- [ODC 192-xx QD](http://r2r.tech/documentation/3d-models/odc-192-xx-qd.md)
- [ODC and WPS Installation for Center Guiding and Web Width Measurement](http://r2r.tech/documentation/manuals/odc-and-wps-installation-center-guiding-and-web-width-measurement.md)
- [Roll-2-Roll® Sensor: ODC Product Brochure](http://r2r.tech/documentation/brochures/roll-2-rollr-sensor-odc-product-brochure.md)
- [SCU5 C(x)D Wiring with ODC (Industrial Ethernet)](http://r2r.tech/documentation/wiring-diagrams/scu5-cxd-wiring-odc-industrial-ethernet.md)
- [SCU5 D Wiring with ODC (Analog Output)](http://r2r.tech/documentation/wiring-diagrams/scu5-d-wiring-odc-analog-output.md)
- [SCU5 DD Wiring with ODC (Digital Output)](http://r2r.tech/documentation/wiring-diagrams/scu5-dd-wiring-odc-digital-output.md)
- [SCU5 DI Wiring with ODC (Digital Input and Output)](http://r2r.tech/documentation/wiring-diagrams/scu5-di-wiring-odc-digital-input-and-output.md)
- [Sensor Installation Recommendations: Inspection Applications](http://r2r.tech/documentation/manuals/sensor-installation-recommendations-inspection-applications.md)
- [WPS 112/221/440/900 or ODC 96/192/288/384/480/768/960 Sensor Installation for to Reduce the Effect of Twist](http://r2r.tech/documentation/manuals/wps-112221440900-or-odc-96192288384480768960-sensor-installation-reduce.md)

---

# ODC 288

URL: https://r2r.tech/products/odc-288.md

## Documentation

**3D Model (STEP):** [1in Mounting Bracket for WPS and ODC Sensors](http://r2r.tech/documentation/3d-models/1in-mounting-bracket-wps-and-odc-sensors.md)

**Additional documentation:**
- [1.5in Mounting Bracket for WPS and ODC Sensors](http://r2r.tech/documentation/3d-models/15in-mounting-bracket-wps-and-odc-sensors.md)
- [Mounting Bracket for 1.5in or 40mm Extrusion for WPS, ODC and 1DC Sensors](http://r2r.tech/documentation/3d-models/mounting-bracket-15in-or-40mm-extrusion-wps-odc-and-1dc-sensors.md)
- [Mounting Bracket for 1in or 25mm Extrusion for WPS, ODC and 1DC Sensors](http://r2r.tech/documentation/3d-models/mounting-bracket-1in-or-25mm-extrusion-wps-odc-and-1dc-sensors.md)
- [New Mounting Brackets for WPS, ODC and 1DC sensors - 1.5 in or 40 mm extrusion](http://r2r.tech/documentation/2d-drawings/new-mounting-brackets-wps-odc-and-1dc-sensors-15-or-40-mm-extrusion.md)
- [New Mounting Brackets for WPS, ODC and 1DC sensors - 1in or 25 mm extrusion](http://r2r.tech/documentation/2d-drawings/new-mounting-brackets-wps-odc-and-1dc-sensors-1in-or-25-mm-extrusion.md)
- [ODC 288-xx QD](http://r2r.tech/documentation/3d-models/odc-288-xx-qd.md)
- [ODC and WPS Installation for Center Guiding and Web Width Measurement](http://r2r.tech/documentation/manuals/odc-and-wps-installation-center-guiding-and-web-width-measurement.md)
- [Roll-2-Roll® Sensor: ODC Product Brochure](http://r2r.tech/documentation/brochures/roll-2-rollr-sensor-odc-product-brochure.md)
- [Sensor Installation Recommendations: Inspection Applications](http://r2r.tech/documentation/manuals/sensor-installation-recommendations-inspection-applications.md)
- [WPS 112/221/440/900 or ODC 96/192/288/384/480/768/960 Sensor Installation for to Reduce the Effect of Twist](http://r2r.tech/documentation/manuals/wps-112221440900-or-odc-96192288384480768960-sensor-installation-reduce.md)

---

# ODC 384

URL: https://r2r.tech/products/sensors/odc-384.md

## Documentation

**3D Model (STEP):** [1in Mounting Bracket for WPS and ODC Sensors](http://r2r.tech/documentation/3d-models/1in-mounting-bracket-wps-and-odc-sensors.md)

**Additional documentation:**
- [1.5in Mounting Bracket for WPS and ODC Sensors](http://r2r.tech/documentation/3d-models/15in-mounting-bracket-wps-and-odc-sensors.md)
- [Mounting Bracket for 1.5in or 40mm Extrusion for WPS, ODC and 1DC Sensors](http://r2r.tech/documentation/3d-models/mounting-bracket-15in-or-40mm-extrusion-wps-odc-and-1dc-sensors.md)
- [Mounting Bracket for 1in or 25mm Extrusion for WPS, ODC and 1DC Sensors](http://r2r.tech/documentation/3d-models/mounting-bracket-1in-or-25mm-extrusion-wps-odc-and-1dc-sensors.md)
- [New Mounting Brackets for WPS, ODC and 1DC sensors - 1.5 in or 40 mm extrusion](http://r2r.tech/documentation/2d-drawings/new-mounting-brackets-wps-odc-and-1dc-sensors-15-or-40-mm-extrusion.md)
- [New Mounting Brackets for WPS, ODC and 1DC sensors - 1in or 25 mm extrusion](http://r2r.tech/documentation/2d-drawings/new-mounting-brackets-wps-odc-and-1dc-sensors-1in-or-25-mm-extrusion.md)
- [ODC 384 xx-QD](http://r2r.tech/documentation/2d-drawings/odc-384-xx-qd.md)
- [ODC 384-xx QD](http://r2r.tech/documentation/3d-models/odc-384-xx-qd.md)
- [ODC and WPS Installation for Center Guiding and Web Width Measurement](http://r2r.tech/documentation/manuals/odc-and-wps-installation-center-guiding-and-web-width-measurement.md)
- [Roll-2-Roll® Sensor: ODC Product Brochure](http://r2r.tech/documentation/brochures/roll-2-rollr-sensor-odc-product-brochure.md)
- [SCU5 C(x)D Wiring with ODC (Industrial Ethernet)](http://r2r.tech/documentation/wiring-diagrams/scu5-cxd-wiring-odc-industrial-ethernet.md)
- [SCU5 D Wiring with ODC (Analog Output)](http://r2r.tech/documentation/wiring-diagrams/scu5-d-wiring-odc-analog-output.md)
- [SCU5 DD Wiring with ODC (Digital Output)](http://r2r.tech/documentation/wiring-diagrams/scu5-dd-wiring-odc-digital-output.md)
- [SCU5 DI Wiring with ODC (Digital Input and Output)](http://r2r.tech/documentation/wiring-diagrams/scu5-di-wiring-odc-digital-input-and-output.md)
- [Sensor Installation Recommendations: Inspection Applications](http://r2r.tech/documentation/manuals/sensor-installation-recommendations-inspection-applications.md)
- [WPS 112/221/440/900 or ODC 96/192/288/384/480/768/960 Sensor Installation for to Reduce the Effect of Twist](http://r2r.tech/documentation/manuals/wps-112221440900-or-odc-96192288384480768960-sensor-installation-reduce.md)

---

# ODC 48

URL: https://r2r.tech/products/sensors/odc-48.md

## Documentation

**3D Model (STEP):** [1in Mounting Bracket for WPS and ODC Sensors](http://r2r.tech/documentation/3d-models/1in-mounting-bracket-wps-and-odc-sensors.md)

**Additional documentation:**
- [1.5in Mounting Bracket for WPS and ODC Sensors](http://r2r.tech/documentation/3d-models/15in-mounting-bracket-wps-and-odc-sensors.md)
- [Mounting Bracket for 1.5in or 40mm Extrusion for WPS, ODC and 1DC Sensors](http://r2r.tech/documentation/3d-models/mounting-bracket-15in-or-40mm-extrusion-wps-odc-and-1dc-sensors.md)
- [Mounting Bracket for 1in or 25mm Extrusion for WPS, ODC and 1DC Sensors](http://r2r.tech/documentation/3d-models/mounting-bracket-1in-or-25mm-extrusion-wps-odc-and-1dc-sensors.md)
- [New Mounting Brackets for WPS, ODC and 1DC sensors - 1.5 in or 40 mm extrusion](http://r2r.tech/documentation/2d-drawings/new-mounting-brackets-wps-odc-and-1dc-sensors-15-or-40-mm-extrusion.md)
- [New Mounting Brackets for WPS, ODC and 1DC sensors - 1in or 25 mm extrusion](http://r2r.tech/documentation/2d-drawings/new-mounting-brackets-wps-odc-and-1dc-sensors-1in-or-25-mm-extrusion.md)
- [ODC 48 xx-QD: 2D Drawing ](http://r2r.tech/documentation/2d-drawings/odc-48-xx-qd-2d-drawing.md)
- [ODC 48-xx QD (1" Mounting w/Left Side Connector)](http://r2r.tech/documentation/3d-models/odc-48-xx-qd-1-mounting-wleft-side-connector.md)
- [ODC 48-xx QD (1" Mounting w/Right Side Connector)](http://r2r.tech/documentation/3d-models/odc-48-xx-qd-1-mounting-wright-side-connector.md)
- [ODC 48-xx QD (NW 17 Rail)](http://r2r.tech/documentation/3d-models/odc-48-xx-qd-nw-17-rail.md)
- [ODC 48-xx QD (No Mounting)](http://r2r.tech/documentation/3d-models/odc-48-xx-qd-no-mounting.md)
- [ODC 48-xx QD w/1in Mounting Bracket](http://r2r.tech/documentation/3d-models/odc-48-xx-qd-w1in-mounting-bracket.md)
- [Roll-2-Roll® Sensor: ODC Product Brochure](http://r2r.tech/documentation/brochures/roll-2-rollr-sensor-odc-product-brochure.md)
- [SCU5 C(x)D Wiring with ODC (Industrial Ethernet)](http://r2r.tech/documentation/wiring-diagrams/scu5-cxd-wiring-odc-industrial-ethernet.md)
- [SCU5 D Wiring with ODC (Analog Output)](http://r2r.tech/documentation/wiring-diagrams/scu5-d-wiring-odc-analog-output.md)
- [SCU5 DD Wiring with ODC (Digital Output)](http://r2r.tech/documentation/wiring-diagrams/scu5-dd-wiring-odc-digital-output.md)
- [SCU5 DI Wiring with ODC (Digital Input and Output)](http://r2r.tech/documentation/wiring-diagrams/scu5-di-wiring-odc-digital-input-and-output.md)
- [Sensor Installation Recommendations: Inspection Applications](http://r2r.tech/documentation/manuals/sensor-installation-recommendations-inspection-applications.md)

---

# ODC 480

URL: https://r2r.tech/products/sensors/odc-480.md

## Documentation

**3D Model (STEP):** [1in Mounting Bracket for WPS and ODC Sensors](http://r2r.tech/documentation/3d-models/1in-mounting-bracket-wps-and-odc-sensors.md)

**Additional documentation:**
- [1.5in Mounting Bracket for WPS and ODC Sensors](http://r2r.tech/documentation/3d-models/15in-mounting-bracket-wps-and-odc-sensors.md)
- [Mounting Bracket for 1.5in or 40mm Extrusion for WPS, ODC and 1DC Sensors](http://r2r.tech/documentation/3d-models/mounting-bracket-15in-or-40mm-extrusion-wps-odc-and-1dc-sensors.md)
- [Mounting Bracket for 1in or 25mm Extrusion for WPS, ODC and 1DC Sensors](http://r2r.tech/documentation/3d-models/mounting-bracket-1in-or-25mm-extrusion-wps-odc-and-1dc-sensors.md)
- [New Mounting Brackets for WPS, ODC and 1DC sensors - 1.5 in or 40 mm extrusion](http://r2r.tech/documentation/2d-drawings/new-mounting-brackets-wps-odc-and-1dc-sensors-15-or-40-mm-extrusion.md)
- [New Mounting Brackets for WPS, ODC and 1DC sensors - 1in or 25 mm extrusion](http://r2r.tech/documentation/2d-drawings/new-mounting-brackets-wps-odc-and-1dc-sensors-1in-or-25-mm-extrusion.md)
- [ODC 480 xx-QD: 2D Drawing ](http://r2r.tech/documentation/2d-drawings/odc-480-xx-qd-2d-drawing.md)
- [ODC 480-xx QD](http://r2r.tech/documentation/3d-models/odc-480-xx-qd.md)
- [ODC and WPS Installation for Center Guiding and Web Width Measurement](http://r2r.tech/documentation/manuals/odc-and-wps-installation-center-guiding-and-web-width-measurement.md)
- [Roll-2-Roll® Sensor: ODC Product Brochure](http://r2r.tech/documentation/brochures/roll-2-rollr-sensor-odc-product-brochure.md)
- [Sensor Installation Recommendations: Inspection Applications](http://r2r.tech/documentation/manuals/sensor-installation-recommendations-inspection-applications.md)
- [WPS 112/221/440/900 or ODC 96/192/288/384/480/768/960 Sensor Installation for to Reduce the Effect of Twist](http://r2r.tech/documentation/manuals/wps-112221440900-or-odc-96192288384480768960-sensor-installation-reduce.md)

---

# ODC 768

URL: https://r2r.tech/products/sensors/odc-768.md

## Documentation

**3D Model (STEP):** [1in Mounting Bracket for WPS and ODC Sensors](http://r2r.tech/documentation/3d-models/1in-mounting-bracket-wps-and-odc-sensors.md)

**Additional documentation:**
- [1.5in Mounting Bracket for WPS and ODC Sensors](http://r2r.tech/documentation/3d-models/15in-mounting-bracket-wps-and-odc-sensors.md)
- [Mounting Bracket for 1.5in or 40mm Extrusion for WPS, ODC and 1DC Sensors](http://r2r.tech/documentation/3d-models/mounting-bracket-15in-or-40mm-extrusion-wps-odc-and-1dc-sensors.md)
- [Mounting Bracket for 1in or 25mm Extrusion for WPS, ODC and 1DC Sensors](http://r2r.tech/documentation/3d-models/mounting-bracket-1in-or-25mm-extrusion-wps-odc-and-1dc-sensors.md)
- [New Mounting Brackets for WPS, ODC and 1DC sensors - 1.5 in or 40 mm extrusion](http://r2r.tech/documentation/2d-drawings/new-mounting-brackets-wps-odc-and-1dc-sensors-15-or-40-mm-extrusion.md)
- [New Mounting Brackets for WPS, ODC and 1DC sensors - 1in or 25 mm extrusion](http://r2r.tech/documentation/2d-drawings/new-mounting-brackets-wps-odc-and-1dc-sensors-1in-or-25-mm-extrusion.md)
- [ODC 768 xx-QD: 2D Drawing ](http://r2r.tech/documentation/2d-drawings/odc-768-xx-qd-2d-drawing.md)
- [ODC 768-xx QD](http://r2r.tech/documentation/3d-models/odc-768-xx-qd.md)
- [ODC and WPS Installation for Center Guiding and Web Width Measurement](http://r2r.tech/documentation/manuals/odc-and-wps-installation-center-guiding-and-web-width-measurement.md)
- [Roll-2-Roll® Sensor: ODC Product Brochure](http://r2r.tech/documentation/brochures/roll-2-rollr-sensor-odc-product-brochure.md)
- [SCU5 C(x)D Wiring with ODC (Industrial Ethernet)](http://r2r.tech/documentation/wiring-diagrams/scu5-cxd-wiring-odc-industrial-ethernet.md)
- [SCU5 D Wiring with ODC (Analog Output)](http://r2r.tech/documentation/wiring-diagrams/scu5-d-wiring-odc-analog-output.md)
- [SCU5 DD Wiring with ODC (Digital Output)](http://r2r.tech/documentation/wiring-diagrams/scu5-dd-wiring-odc-digital-output.md)
- [SCU5 DI Wiring with ODC (Digital Input and Output)](http://r2r.tech/documentation/wiring-diagrams/scu5-di-wiring-odc-digital-input-and-output.md)
- [Sensor Installation Recommendations: Inspection Applications](http://r2r.tech/documentation/manuals/sensor-installation-recommendations-inspection-applications.md)
- [WPS 112/221/440/900 or ODC 96/192/288/384/480/768/960 Sensor Installation for to Reduce the Effect of Twist](http://r2r.tech/documentation/manuals/wps-112221440900-or-odc-96192288384480768960-sensor-installation-reduce.md)

---

# ODC 96

URL: https://r2r.tech/products/sensors/odc-96.md

## Documentation

**3D Model (STEP):** [1in Mounting Bracket for WPS and ODC Sensors](http://r2r.tech/documentation/3d-models/1in-mounting-bracket-wps-and-odc-sensors.md)

**Additional documentation:**
- [1.5in Mounting Bracket for WPS and ODC Sensors](http://r2r.tech/documentation/3d-models/15in-mounting-bracket-wps-and-odc-sensors.md)
- [Mounting Bracket for 1.5in or 40mm Extrusion for WPS, ODC and 1DC Sensors](http://r2r.tech/documentation/3d-models/mounting-bracket-15in-or-40mm-extrusion-wps-odc-and-1dc-sensors.md)
- [Mounting Bracket for 1in or 25mm Extrusion for WPS, ODC and 1DC Sensors](http://r2r.tech/documentation/3d-models/mounting-bracket-1in-or-25mm-extrusion-wps-odc-and-1dc-sensors.md)
- [New Mounting Brackets for WPS, ODC and 1DC sensors - 1.5 in or 40 mm extrusion](http://r2r.tech/documentation/2d-drawings/new-mounting-brackets-wps-odc-and-1dc-sensors-15-or-40-mm-extrusion.md)
- [New Mounting Brackets for WPS, ODC and 1DC sensors - 1in or 25 mm extrusion](http://r2r.tech/documentation/2d-drawings/new-mounting-brackets-wps-odc-and-1dc-sensors-1in-or-25-mm-extrusion.md)
- [ODC 96 xx-QD](http://r2r.tech/documentation/2d-drawings/odc-96-xx-qd.md)
- [ODC 96-xx QD](http://r2r.tech/documentation/3d-models/odc-96-xx-qd.md)
- [ODC and WPS Installation for Center Guiding and Web Width Measurement](http://r2r.tech/documentation/manuals/odc-and-wps-installation-center-guiding-and-web-width-measurement.md)
- [Roll-2-Roll® Sensor: ODC Product Brochure](http://r2r.tech/documentation/brochures/roll-2-rollr-sensor-odc-product-brochure.md)
- [SCU5 C(x)D Wiring with ODC (Industrial Ethernet)](http://r2r.tech/documentation/wiring-diagrams/scu5-cxd-wiring-odc-industrial-ethernet.md)
- [SCU5 D Wiring with ODC (Analog Output)](http://r2r.tech/documentation/wiring-diagrams/scu5-d-wiring-odc-analog-output.md)
- [SCU5 DD Wiring with ODC (Digital Output)](http://r2r.tech/documentation/wiring-diagrams/scu5-dd-wiring-odc-digital-output.md)
- [SCU5 DI Wiring with ODC (Digital Input and Output)](http://r2r.tech/documentation/wiring-diagrams/scu5-di-wiring-odc-digital-input-and-output.md)
- [Sensor Installation Recommendations: Inspection Applications](http://r2r.tech/documentation/manuals/sensor-installation-recommendations-inspection-applications.md)
- [WPS 112/221/440/900 or ODC 96/192/288/384/480/768/960 Sensor Installation for to Reduce the Effect of Twist](http://r2r.tech/documentation/manuals/wps-112221440900-or-odc-96192288384480768960-sensor-installation-reduce.md)

---

# ODC 960

URL: https://r2r.tech/products/sensors/odc-960.md

## Documentation

**3D Model (STEP):** [1in Mounting Bracket for WPS and ODC Sensors](http://r2r.tech/documentation/3d-models/1in-mounting-bracket-wps-and-odc-sensors.md)

**Additional documentation:**
- [1.5in Mounting Bracket for WPS and ODC Sensors](http://r2r.tech/documentation/3d-models/15in-mounting-bracket-wps-and-odc-sensors.md)
- [Mounting Bracket for 1.5in or 40mm Extrusion for WPS, ODC and 1DC Sensors](http://r2r.tech/documentation/3d-models/mounting-bracket-15in-or-40mm-extrusion-wps-odc-and-1dc-sensors.md)
- [Mounting Bracket for 1in or 25mm Extrusion for WPS, ODC and 1DC Sensors](http://r2r.tech/documentation/3d-models/mounting-bracket-1in-or-25mm-extrusion-wps-odc-and-1dc-sensors.md)
- [New Mounting Brackets for WPS, ODC and 1DC sensors - 1.5 in or 40 mm extrusion](http://r2r.tech/documentation/2d-drawings/new-mounting-brackets-wps-odc-and-1dc-sensors-15-or-40-mm-extrusion.md)
- [New Mounting Brackets for WPS, ODC and 1DC sensors - 1in or 25 mm extrusion](http://r2r.tech/documentation/2d-drawings/new-mounting-brackets-wps-odc-and-1dc-sensors-1in-or-25-mm-extrusion.md)
- [ODC 960 xx-QD](http://r2r.tech/documentation/2d-drawings/odc-960-xx-qd.md)
- [ODC 960 xx-QD: 2D Drawing (dxf)](http://r2r.tech/documentation/2d-drawings/odc-960-xx-qd-2d-drawing-dxf.md)
- [ODC 960-xx QD](http://r2r.tech/documentation/3d-models/odc-960-xx-qd.md)
- [ODC and WPS Installation for Center Guiding and Web Width Measurement](http://r2r.tech/documentation/manuals/odc-and-wps-installation-center-guiding-and-web-width-measurement.md)
- [Roll-2-Roll® Sensor: ODC Product Brochure](http://r2r.tech/documentation/brochures/roll-2-rollr-sensor-odc-product-brochure.md)
- [Sensor Installation Recommendations: Inspection Applications](http://r2r.tech/documentation/manuals/sensor-installation-recommendations-inspection-applications.md)
- [WPS 112/221/440/900 or ODC 96/192/288/384/480/768/960 Sensor Installation for to Reduce the Effect of Twist](http://r2r.tech/documentation/manuals/wps-112221440900-or-odc-96192288384480768960-sensor-installation-reduce.md)

---

# RLA Series

URL: https://r2r.tech/products/actuators/rla.md

## Documentation

**3D Model (STEP):** [RLA-050-0600-TG](http://r2r.tech/documentation/3d-models/rla-050-0600-tg.md)

**Additional documentation:**
- [BLA-0xx-0600-TG 2D Drawing](http://r2r.tech/documentation/2d-drawings/bla-0xx-0600-tg-2d-drawing.md)
- [CASE STUDY - Pneumo-Hydraulic Web Guide Upgrade](http://r2r.tech/documentation/case-studies/case-study-pneumo-hydraulic-web-guide-upgrade.md)
- [CASE STUDY: Web Guide Upgrade Kit for Aging Web Guides](http://r2r.tech/documentation/case-studies/case-study-web-guide-upgrade-kit-aging-web-guides.md)
- [CASE STUDY: Web Guide Upgrade of Pneumo-hydraulic Web Guide for a Slitting Operation](http://r2r.tech/documentation/case-studies/case-study-web-guide-upgrade-pneumo-hydraulic-web-guide-slitting.md)
- [LHS-005-0125-LP: 2D Drawing (dxf)](http://r2r.tech/documentation/2d-drawings/lhs-005-0125-lp-2d-drawing-dxf.md)
- [LHS-005-0400-LP: 2D Drawing (dxf)](http://r2r.tech/documentation/2d-drawings/lhs-005-0400-lp-2d-drawing-dxf.md)
- [LHS-005-0xxx-LP: 2D Drawing (pdf)](http://r2r.tech/documentation/2d-drawings/lhs-005-0xxx-lp-2d-drawing-pdf.md)
- [LHS-015-0150-WG: 2D Drawing (pdf)](http://r2r.tech/documentation/2d-drawings/lhs-015-0150-wg-2d-drawing-pdf.md)
- [LHS-020-0xxx-RF: 2D Drawing (dxf)](http://r2r.tech/documentation/2d-drawings/lhs-020-0xxx-rf-2d-drawing-dxf.md)
- [LHS-020-0xxx-RF: 2D Drawing (pdf)](http://r2r.tech/documentation/2d-drawings/lhs-020-0xxx-rf-2d-drawing-pdf.md)
- [LHS-030-xxxx-RF: 2D Drawing (pdf)](http://r2r.tech/documentation/2d-drawings/lhs-030-xxxx-rf-2d-drawing-pdf.md)
- [Power Supply Regen Clamp Wiring](http://r2r.tech/documentation/wiring-diagrams/power-supply-regen-clamp-wiring.md)
- [RLA-050-0600-TG: 2D Drawing (pdf)](http://r2r.tech/documentation/2d-drawings/rla-050-0600-tg-2d-drawing-pdf.md)
- [Roll-2-Roll® Actuators Brochure](http://r2r.tech/documentation/brochures/roll-2-rollr-actuators-brochure.md)
- [Roll-2-Roll® Upgrade Kit: Product Brochure](http://r2r.tech/documentation/brochures/roll-2-rollr-upgrade-kit-product-brochure.md)
- [Roll-2-Roll® Web Guide Upgrade Kit Product Brochure](http://r2r.tech/documentation/brochures/roll-2-rollr-web-guide-upgrade-kit-product-brochure.md)
- [SCU5 MD Wiring with MC QD 1141/1140/1240 + Web Guide Actuator](http://r2r.tech/documentation/wiring-diagrams/scu5-md-wiring-mc-qd-114111401240-web-guide-actuator.md)
- [SCU5 MD Wiring with MC QD 1180/1181/1211/1230/1231/1260 + Regen Clamp + Unwind/Rewind Actuator](http://r2r.tech/documentation/wiring-diagrams/scu5-md-wiring-mc-qd-118011811211123012311260-regen-clamp.md)
- [SCU5 MD Wiring with MC QD 1180/1181/1211/1230/1231/1260 + Web Guide Actuator](http://r2r.tech/documentation/wiring-diagrams/scu5-md-wiring-mc-qd-118011811211123012311260-web-guide-actuator.md)
- [SCU6x MxD Wiring Diagram with Unwind/Rewind (Small Load)](http://r2r.tech/documentation/wiring-diagrams/scu6x-mxd-wiring-diagram-unwindrewind-small-load.md)
- [Servo Center Servo Installation](http://r2r.tech/documentation/manuals/servo-center-servo-installation.md)
- [Unwind/Rewind Guides Brochure](http://r2r.tech/documentation/brochures/unwindrewind-guides-brochure.md)
- [Unwind/Rewind Installation Checklist](http://r2r.tech/documentation/manuals/unwindrewind-installation-checklist.md)

---

# Roll-2-Roll Steering Guide

URL: https://r2r.tech/products/web-guides/steering-guide.md

## Documentation


**Additional documentation:**
- [ARIS SCU5 EtherNet/IP Configuration Manual](http://r2r.tech/documentation/manuals/aris-scu5-ethernetip-configuration-manual.md)
- [Installation of Steering Guide](http://r2r.tech/documentation/manuals/installation-steering-guide.md)
- [Motor Driver MC QD 1140/1141/1161/1180/1181/1211/1230/1231/1240/1260](http://r2r.tech/documentation/manuals/motor-driver-mc-qd-1140114111611180118112111230123112401260.md)
- [Narrow Web Steering Guides Product Brochure](http://r2r.tech/documentation/brochures/narrow-web-steering-guides-product-brochure.md)
- [Roll-2-Roll® Web Guides: Product Brochure](http://r2r.tech/documentation/brochures/roll-2-rollr-web-guides-product-brochure.md)
- [SCU5 MD Wiring with MC QD 1141/1140/1240 + Web Guide Actuator](http://r2r.tech/documentation/wiring-diagrams/scu5-md-wiring-mc-qd-114111401240-web-guide-actuator.md)
- [SCU5 MD Wiring with ODC Sensor, MC QD 1140/1141/1240 with Web Guide](http://r2r.tech/documentation/wiring-diagrams/scu5-md-wiring-odc-sensor-mc-qd-114011411240-web-guide.md)
- [SCU5: Sensor and Web Guide Controller User Manual v3.4](http://r2r.tech/documentation/manuals/scu5-sensor-and-web-guide-controller-user-manual-v34.md)
- [Servo Center Servo Installation](http://r2r.tech/documentation/manuals/servo-center-servo-installation.md)
- [Standard Operating Procedure (SOP): Center Guiding Application (v2.x)](http://r2r.tech/documentation/manuals/standard-operating-procedure-sop-center-guiding-application-v2x.md)
- [Standard Operating Procedure (SOP): Edge Guiding Application (v2.x)](http://r2r.tech/documentation/manuals/standard-operating-procedure-sop-edge-guiding-application-v2x.md)
- [Standard Operating Procedure (SOP): Line Guiding Application](http://r2r.tech/documentation/manuals/standard-operating-procedure-sop-line-guiding-application.md)
- [Web Guide Installation Checklist](http://r2r.tech/documentation/manuals/web-guide-installation-checklist.md)

---

# Roll-2-Roll Unwind/Rewind Guide

URL: https://r2r.tech/products/unwind-rewind-guide.md

## Documentation


**Additional documentation:**
- [BLA-0xx-0600-TG 2D Drawing](http://r2r.tech/documentation/2d-drawings/bla-0xx-0600-tg-2d-drawing.md)
- [CASE STUDY - Pneumo-Hydraulic Web Guide Upgrade](http://r2r.tech/documentation/case-studies/case-study-pneumo-hydraulic-web-guide-upgrade.md)
- [CASE STUDY: Web Guide Upgrade Kit for Aging Web Guides](http://r2r.tech/documentation/case-studies/case-study-web-guide-upgrade-kit-aging-web-guides.md)
- [CASE STUDY: Web Guide Upgrade of Pneumo-hydraulic Web Guide for a Slitting Operation](http://r2r.tech/documentation/case-studies/case-study-web-guide-upgrade-pneumo-hydraulic-web-guide-slitting.md)
- [LHS-005-0125-LP: 2D Drawing (dxf)](http://r2r.tech/documentation/2d-drawings/lhs-005-0125-lp-2d-drawing-dxf.md)
- [LHS-005-0400-LP: 2D Drawing (dxf)](http://r2r.tech/documentation/2d-drawings/lhs-005-0400-lp-2d-drawing-dxf.md)
- [LHS-005-0xxx-LP: 2D Drawing (pdf)](http://r2r.tech/documentation/2d-drawings/lhs-005-0xxx-lp-2d-drawing-pdf.md)
- [LHS-015-0150-WG: 2D Drawing (pdf)](http://r2r.tech/documentation/2d-drawings/lhs-015-0150-wg-2d-drawing-pdf.md)
- [LHS-020-0xxx-RF: 2D Drawing (dxf)](http://r2r.tech/documentation/2d-drawings/lhs-020-0xxx-rf-2d-drawing-dxf.md)
- [LHS-020-0xxx-RF: 2D Drawing (pdf)](http://r2r.tech/documentation/2d-drawings/lhs-020-0xxx-rf-2d-drawing-pdf.md)
- [LHS-030-xxxx-RF: 2D Drawing (pdf)](http://r2r.tech/documentation/2d-drawings/lhs-030-xxxx-rf-2d-drawing-pdf.md)
- [Master/Slave Web Guiding System Installation](http://r2r.tech/documentation/manuals/masterslave-web-guiding-system-installation.md)
- [Motor Controller - MC QD 1140/1141/1240/1241: 2D Drawing](http://r2r.tech/documentation/2d-drawings/motor-controller-mc-qd-1140114112401241-2d-drawing.md)
- [Motor Controller - MC QD 1140/1141/1240/1241: 2D Drawing (DXF)](http://r2r.tech/documentation/2d-drawings/motor-controller-mc-qd-1140114112401241-2d-drawing-dxf.md)
- [Motor Controller - MC QD 1180/1181/1211/1230/1231/1260: 2D Drawing](http://r2r.tech/documentation/2d-drawings/motor-controller-mc-qd-118011811211123012311260-2d-drawing.md)
- [Motor Driver MC QD 1140/1141/1161/1180/1181/1211/1230/1231/1240/1260](http://r2r.tech/documentation/manuals/motor-driver-mc-qd-1140114111611180118112111230123112401260.md)
- [Power Supply Regen Clamp Wiring](http://r2r.tech/documentation/wiring-diagrams/power-supply-regen-clamp-wiring.md)
- [RLA-050-0600-TG: 2D Drawing (pdf)](http://r2r.tech/documentation/2d-drawings/rla-050-0600-tg-2d-drawing-pdf.md)
- [Retrofit Actuator - LHS-0xx-xxxx-TG: 2D Drawing (DXF)](http://r2r.tech/documentation/2d-drawings/retrofit-actuator-lhs-0xx-xxxx-tg-2d-drawing-dxf.md)
- [Retrofit Installation Checklist](http://r2r.tech/documentation/manuals/retrofit-installation-checklist.md)
- [Roll-2-Roll® Actuators Brochure](http://r2r.tech/documentation/brochures/roll-2-rollr-actuators-brochure.md)
- [Roll-2-Roll® Upgrade Kit: Product Brochure](http://r2r.tech/documentation/brochures/roll-2-rollr-upgrade-kit-product-brochure.md)
- [Roll-2-Roll® Web Guide Upgrade Kit Product Brochure](http://r2r.tech/documentation/brochures/roll-2-rollr-web-guide-upgrade-kit-product-brochure.md)
- [Roll-2-Roll® Web Guides: Product Brochure](http://r2r.tech/documentation/brochures/roll-2-rollr-web-guides-product-brochure.md)
- [SCU5 Controller: 2D Drawing (DXF)](http://r2r.tech/documentation/2d-drawings/scu5-controller-2d-drawing-dxf.md)
- [SCU5 Controller: 2D Drawing (pdf)](http://r2r.tech/documentation/2d-drawings/scu5-controller-2d-drawing-pdf.md)
- [SCU5 MD Wiring with MC QD 1141/1140/1240 + Web Guide Actuator](http://r2r.tech/documentation/wiring-diagrams/scu5-md-wiring-mc-qd-114111401240-web-guide-actuator.md)
- [SCU5 MD Wiring with MC QD 1180/1181/1211/1230/1231/1260 + Large Upgrade Actuator](http://r2r.tech/documentation/wiring-diagrams/scu5-md-wiring-mc-qd-118011811211123012311260-large-upgrade-actuator.md)
- [SCU5 MD Wiring with MC QD 1180/1181/1211/1230/1231/1260 + Regen Clamp + Unwind/Rewind Actuator](http://r2r.tech/documentation/wiring-diagrams/scu5-md-wiring-mc-qd-118011811211123012311260-regen-clamp.md)
- [SCU5 MD Wiring with MC QD 1180/1181/1211/1230/1231/1260 + Web Guide Actuator](http://r2r.tech/documentation/wiring-diagrams/scu5-md-wiring-mc-qd-118011811211123012311260-web-guide-actuator.md)
- [SCU5: Sensor and Web Guide Controller User Manual v3.4](http://r2r.tech/documentation/manuals/scu5-sensor-and-web-guide-controller-user-manual-v34.md)
- [SCU6x MxD Wiring Diagram with Unwind/Rewind (Small Load)](http://r2r.tech/documentation/wiring-diagrams/scu6x-mxd-wiring-diagram-unwindrewind-small-load.md)
- [Servo Center Servo Installation](http://r2r.tech/documentation/manuals/servo-center-servo-installation.md)
- [Standard Operating Procedure (SOP): Center Guiding Application (v2.x)](http://r2r.tech/documentation/manuals/standard-operating-procedure-sop-center-guiding-application-v2x.md)
- [Standard Operating Procedure (SOP): Edge Guiding Application (v2.x)](http://r2r.tech/documentation/manuals/standard-operating-procedure-sop-edge-guiding-application-v2x.md)
- [Standard Operating Procedure (SOP): Line Guiding Application](http://r2r.tech/documentation/manuals/standard-operating-procedure-sop-line-guiding-application.md)
- [Unwind/Rewind Guides Brochure](http://r2r.tech/documentation/brochures/unwindrewind-guides-brochure.md)
- [Unwind/Rewind Installation Checklist](http://r2r.tech/documentation/manuals/unwindrewind-installation-checklist.md)
- [Web Guide Installation Checklist](http://r2r.tech/documentation/manuals/web-guide-installation-checklist.md)

---

# SCU5

URL: https://r2r.tech/products/controller/scu5.md

## Documentation

**3D Model (STEP):** [SCU5](http://r2r.tech/documentation/3d-models/scu5.md)

**Additional documentation:**
- [24 V DC Input Power Cable 2D Drawing](http://r2r.tech/documentation/2d-drawings/24-v-dc-input-power-cable-2d-drawing.md)
- [ARIS SCU5 EtherNet/IP Configuration Manual](http://r2r.tech/documentation/manuals/aris-scu5-ethernetip-configuration-manual.md)
- [CASE STUDY - Pneumo-Hydraulic Web Guide Upgrade](http://r2r.tech/documentation/case-studies/case-study-pneumo-hydraulic-web-guide-upgrade.md)
- [CASE STUDY: Compact Web Guide with Ethernet Communication](http://r2r.tech/documentation/case-studies/case-study-compact-web-guide-ethernet-communication.md)
- [CASE STUDY: Pneumo-hydraulic Web Guide Upgrade of a GWD Web Guide MA 2200](http://r2r.tech/documentation/case-studies/case-study-pneumo-hydraulic-web-guide-upgrade-gwd-web-guide-ma-2200.md)
- [CASE STUDY: Web Guide Sensor Upgrade - Metal Lamination](http://r2r.tech/documentation/case-studies/case-study-web-guide-sensor-upgrade-metal-lamination.md)
- [CASE STUDY: Web Guide Upgrade Kit for Aging Web Guides](http://r2r.tech/documentation/case-studies/case-study-web-guide-upgrade-kit-aging-web-guides.md)
- [CASE STUDY: Web Guide Upgrade of Pneumo-hydraulic Web Guide for a Slitting Operation](http://r2r.tech/documentation/case-studies/case-study-web-guide-upgrade-pneumo-hydraulic-web-guide-slitting.md)
- [Case Study - Line Guiding Application](http://r2r.tech/documentation/case-studies/case-study-line-guiding-application.md)
- [Case Study - Pneumo-hydraulic North American Web Guide Upgrade](http://r2r.tech/documentation/case-studies/case-study-pneumo-hydraulic-north-american-web-guide-upgrade.md)
- [Case Study - Uneven Edge Guiding - Specialty Sensing](http://r2r.tech/documentation/case-studies/case-study-uneven-edge-guiding-specialty-sensing.md)
- [Case Study - Web Guide Upgrade with Roll-2-Roll Web Guide Upgrade Kit](http://r2r.tech/documentation/case-studies/case-study-web-guide-upgrade-roll-2-roll-web-guide-upgrade-kit.md)
- [Case Study - Wide Web Guide System for Textiles](http://r2r.tech/documentation/case-studies/case-study-wide-web-guide-system-textiles.md)
- [Case Study Contrast Sensing Web Guiding for Textiles Converting](http://r2r.tech/documentation/case-studies/case-study-contrast-sensing-web-guiding-textiles-converting.md)
- [EtherCAT ECS File for SCU5 firmware Version 3.5+ using Hilscher Module](http://r2r.tech/documentation/support-files/ethercat-ecs-file-scu5-firmware-version-35-using-hilscher-module.md)
- [EtherNet/IP EDS File for SCU5 firmware Version 3.5+ using HMS Module](http://r2r.tech/documentation/support-files/ethernetip-eds-file-scu5-firmware-version-35-using-hms-module.md)
- [EtherNet/IP EDS File for SCU5 firmware Version 3.5+ using Hilscher Module](http://r2r.tech/documentation/support-files/ethernetip-eds-file-scu5-firmware-version-35-using-hilscher-module.md)
- [Motor Controller - MC QD 1180/1181/1211/1230/1231/1260: 2D Drawing](http://r2r.tech/documentation/2d-drawings/motor-controller-mc-qd-118011811211123012311260-2d-drawing.md)
- [PROFINET GSDML File for SCU5 firmware Version 3.5+ using HMS Module](http://r2r.tech/documentation/support-files/profinet-gsdml-file-scu5-firmware-version-35-using-hms-module.md)
- [PROFINET GSDML File for SCU5 firmware Version 3.5+ using Hilscher Module](http://r2r.tech/documentation/support-files/profinet-gsdml-file-scu5-firmware-version-35-using-hilscher-module.md)
- [RTI + SCU5 C(E)D Wiring with 2x ODC for Web Width Measurement](http://r2r.tech/documentation/wiring-diagrams/rti-scu5-ced-wiring-2x-odc-web-width-measurement.md)
- [RTI + SCU5 C(E)D Wiring with 2x ODC for Web Width Measurement with Stacklight](http://r2r.tech/documentation/wiring-diagrams/rti-scu5-ced-wiring-2x-odc-web-width-measurement-stacklight.md)
- [RTI + SCU5 MC(E)D Wiring with MC QD 1140/1141/1240 with Retrofit Actuator](http://r2r.tech/documentation/wiring-diagrams/rti-scu5-mced-wiring-mc-qd-114011411240-retrofit-actuator.md)
- [Remote Touch Screen Operator Interface (RTI) User Manual](http://r2r.tech/documentation/manuals/remote-touch-screen-operator-interface-rti-user-manual.md)
- [Rockwell/AB Add-on Instructions for SCU5 C(E)D/MC(E)D controller v3.5d](http://r2r.tech/documentation/support-files/rockwellab-add-instructions-scu5-cedmced-controller-v35d.md)
- [Rockwell/AB Add-on Instructions for SCU5 C(E)D/MC(E)D controller v3.6c](http://r2r.tech/documentation/support-files/rockwellab-add-instructions-scu5-cedmced-controller-v36c.md)
- [Rockwell/AB Add-on Instructions for SCU5 C(E)D/MC(E)D controller v3.6g](http://r2r.tech/documentation/support-files/rockwellab-add-instructions-scu5-cedmced-controller-v36g.md)
- [Rockwell/AB Add-on Instructions for SCU5 C(E)D/MC(E)D controller v3.6i](http://r2r.tech/documentation/support-files/rockwellab-add-instructions-scu5-cedmced-controller-v36i.md)
- [Rockwell/AB Add-on Instructions for SCU5 C(E)D/MC(E)D controller v3.6l](http://r2r.tech/documentation/support-files/rockwellab-add-instructions-scu5-cedmced-controller-v36l.md)
- [Roll-2-Roll® Controller Product Brochure](http://r2r.tech/documentation/brochures/roll-2-rollr-controller-product-brochure.md)
- [SCU5 C(x)D Wiring with ODC (Industrial Ethernet)](http://r2r.tech/documentation/wiring-diagrams/scu5-cxd-wiring-odc-industrial-ethernet.md)
- [SCU5 C(x)D Wiring with WPS Sensor (Industrial Ethernet)](http://r2r.tech/documentation/wiring-diagrams/scu5-cxd-wiring-wps-sensor-industrial-ethernet.md)
- [SCU5 Controller: 2D Drawing (DXF)](http://r2r.tech/documentation/2d-drawings/scu5-controller-2d-drawing-dxf.md)
- [SCU5 Controller: 2D Drawing (pdf)](http://r2r.tech/documentation/2d-drawings/scu5-controller-2d-drawing-pdf.md)
- [SCU5 D Wiring with ODC (Analog Output)](http://r2r.tech/documentation/wiring-diagrams/scu5-d-wiring-odc-analog-output.md)
- [SCU5 D Wiring with WPS Sensor (Analog Output)](http://r2r.tech/documentation/wiring-diagrams/scu5-d-wiring-wps-sensor-analog-output.md)
- [SCU5 DD Opto-Isolated Output Documentation](http://r2r.tech/documentation/manuals/scu5-dd-opto-isolated-output-documentation.md)
- [SCU5 DD Wiring with ODC (Digital Output)](http://r2r.tech/documentation/wiring-diagrams/scu5-dd-wiring-odc-digital-output.md)
- [SCU5 DD Wiring with WPS Sensor (Digital Output)](http://r2r.tech/documentation/wiring-diagrams/scu5-dd-wiring-wps-sensor-digital-output.md)
- [SCU5 DI Wiring with ODC (Digital Input and Output)](http://r2r.tech/documentation/wiring-diagrams/scu5-di-wiring-odc-digital-input-and-output.md)
- [SCU5 DI Wiring with WPS Sensor (Digital Input and Output)](http://r2r.tech/documentation/wiring-diagrams/scu5-di-wiring-wps-sensor-digital-input-and-output.md)
- [SCU5 M: Web Guide Controller Product and User Manual (V2.6)](http://r2r.tech/documentation/manuals/scu5-m-web-guide-controller-product-and-user-manual-v26.md)
- [SCU5 MC(x)D Wiring with MC QD 1141/1140/1240 + Web Guide Actuator](http://r2r.tech/documentation/wiring-diagrams/scu5-mcxd-wiring-mc-qd-114111401240-web-guide-actuator.md)
- [SCU5 MD Wiring with MC QD 1141/1140/1240 + Web Guide Actuator](http://r2r.tech/documentation/wiring-diagrams/scu5-md-wiring-mc-qd-114111401240-web-guide-actuator.md)
- [SCU5 MD Wiring with MC QD 1180/1181/1211/1230/1231/1260 + Large Upgrade Actuator](http://r2r.tech/documentation/wiring-diagrams/scu5-md-wiring-mc-qd-118011811211123012311260-large-upgrade-actuator.md)
- [SCU5 MD Wiring with MC QD 1180/1181/1211/1230/1231/1260 + Regen Clamp + Unwind/Rewind Actuator](http://r2r.tech/documentation/wiring-diagrams/scu5-md-wiring-mc-qd-118011811211123012311260-regen-clamp.md)
- [SCU5 MD Wiring with MC QD 1180/1181/1211/1230/1231/1260 + Web Guide Actuator](http://r2r.tech/documentation/wiring-diagrams/scu5-md-wiring-mc-qd-118011811211123012311260-web-guide-actuator.md)
- [SCU5 MD Wiring with ODC Sensor, MC QD 1140/1141/1240 with Web Guide](http://r2r.tech/documentation/wiring-diagrams/scu5-md-wiring-odc-sensor-mc-qd-114011411240-web-guide.md)
- [SCU5 MDIO Wiring with MC QD 1141/1140/1240 + Web Guide Actuator](http://r2r.tech/documentation/wiring-diagrams/scu5-mdio-wiring-mc-qd-114111401240-web-guide-actuator.md)
- [SCU5 MDIO: Digitial Input and Output Documentation](http://r2r.tech/documentation/manuals/scu5-mdio-digitial-input-and-output-documentation.md)
- [SCU5 xC(x)D Register Map for v3.5](http://r2r.tech/documentation/manuals/scu5-xcxd-register-map-v35.md)
- [SCU5 xC(x)D Register Map for v3.6](http://r2r.tech/documentation/manuals/scu5-xcxd-register-map-v36.md)
- [SCU5 xC(x)D Register Map for v3.6d](http://r2r.tech/documentation/manuals/scu5-xcxd-register-map-v36d.md)
- [SCU5 xC(x)D Register Map for v3.6g](http://r2r.tech/documentation/manuals/scu5-xcxd-register-map-v36g.md)
- [SCU5 xC(x)D Register Map for v3.6i](http://r2r.tech/documentation/manuals/scu5-xcxd-register-map-v36i.md)
- [SCU5: Sensor and Web Guide Controller User Manual v3.3](http://r2r.tech/documentation/manuals/scu5-sensor-and-web-guide-controller-user-manual-v33.md)
- [SCU5: Sensor and Web Guide Controller User Manual v3.4](http://r2r.tech/documentation/manuals/scu5-sensor-and-web-guide-controller-user-manual-v34.md)
- [SCU5: Sensor and Web Guide Controller User Manual v3.6](http://r2r.tech/documentation/manuals/scu5-sensor-and-web-guide-controller-user-manual-v36.md)
- [SCU5: Sensor and Web Guide Controller User Manual v3.6d+](http://r2r.tech/documentation/manuals/scu5-sensor-and-web-guide-controller-user-manual-v36d.md)
- [SCU5: Sensor and Web Guide Controller User Manual v3.6n+](http://r2r.tech/documentation/manuals/scu5-sensor-and-web-guide-controller-user-manual-v36n.md)
- [SCU6x Product Brochure](http://r2r.tech/documentation/brochures/scu6x-product-brochure.md)
- [SCU6x: 2D Drawing (pdf)](http://r2r.tech/documentation/2d-drawings/scu6x-2d-drawing-pdf.md)
- [SCU6x: 2D Drawing SCUx Connectors (dxf)](http://r2r.tech/documentation/2d-drawings/scu6x-2d-drawing-scux-connectors-dxf.md)
- [Servo Center Sensor - 2D Drawing](http://r2r.tech/documentation/2d-drawings/servo-center-sensor-2d-drawing.md)
- [Standard Operating Procedure (SOP): Center Guiding Application (v2.x)](http://r2r.tech/documentation/manuals/standard-operating-procedure-sop-center-guiding-application-v2x.md)
- [Standard Operating Procedure (SOP): Edge Guiding Application (v2.x)](http://r2r.tech/documentation/manuals/standard-operating-procedure-sop-edge-guiding-application-v2x.md)
- [Standard Operating Procedure (SOP): Edge Guiding Application (v3.x)](http://r2r.tech/documentation/manuals/standard-operating-procedure-sop-edge-guiding-application-v3x.md)
- [Standard Operating Procedure (SOP): Line Guiding Application](http://r2r.tech/documentation/manuals/standard-operating-procedure-sop-line-guiding-application.md)
- [Standard Operating Procedure - Center Guiding Application (v3.x)](http://r2r.tech/documentation/manuals/standard-operating-procedure-center-guiding-application-v3x.md)
- [Web Guide: Disturbance Rejection Performance](http://r2r.tech/documentation/white-papers/web-guide-disturbance-rejection-performance.md)
- [Web Guides: Dynamic Performance with High Speed Actuator](http://r2r.tech/documentation/white-papers/web-guides-dynamic-performance-high-speed-actuator.md)
- [Web Guides: How to Quantify the Dynamic Performance?](http://r2r.tech/documentation/white-papers/web-guides-how-quantify-dynamic-performance.md)

---

# SCU6x

URL: https://r2r.tech/products/controller/scu6x.md

## Documentation

**3D Model (STEP):** [SCU6x](http://r2r.tech/documentation/3d-models/scu6x.md)

**Additional documentation:**
- [EtherNet/IP EDS File for Roll-2-Roll® Communication Module](http://r2r.tech/documentation/support-files/ethernetip-eds-file-roll-2-rollr-communication-module.md)
- [EtherNet/IP EDS File for SCU6x firmware Version 4.1+ using Hilscher Module](http://r2r.tech/documentation/support-files/ethernetip-eds-file-scu6x-firmware-version-41-using-hilscher-module.md)
- [Rockwell/AB Add-on Instructions for SCU6x C(E)D/MC(E)D controller v4.1+](http://r2r.tech/documentation/support-files/rockwellab-add-instructions-scu6x-cedmced-controller-v41.md)
- [Roll-2-Roll® Control Center Pro Software (Windows)](http://r2r.tech/documentation/software/roll-2-rollr-control-center-pro-software-windows.md)
- [Roll-2-Roll® Control Center Software (Windows)](http://r2r.tech/documentation/software/roll-2-rollr-control-center-software-windows.md)
- [SCU6x Industrial Ethernet Register Map for v4.1+](http://r2r.tech/documentation/manuals/scu6x-industrial-ethernet-register-map-v41.md)
- [SCU6x MD Wiring Diagram with Retrofit/Upgrade Actuator](http://r2r.tech/documentation/wiring-diagrams/scu6x-md-wiring-diagram-retrofitupgrade-actuator.md)
- [SCU6x MD Wiring Diagram with Web Guide](http://r2r.tech/documentation/wiring-diagrams/scu6x-md-wiring-diagram-web-guide.md)
- [SCU6x MxD Wiring Diagram with Unwind/Rewind (Small Load)](http://r2r.tech/documentation/wiring-diagrams/scu6x-mxd-wiring-diagram-unwindrewind-small-load.md)
- [SCU6x MxD Wiring Diagram with Unwind/Rewind Actuator](http://r2r.tech/documentation/wiring-diagrams/scu6x-mxd-wiring-diagram-unwindrewind-actuator.md)
- [SCU6x MxD Wiring Diagram with Unwind/Rewind Actuator with Regen Clamp](http://r2r.tech/documentation/wiring-diagrams/scu6x-mxd-wiring-diagram-unwindrewind-actuator-regen-clamp.md)
- [SCU6x MxD Wiring Diagram with Unwind/Rewind Actuator without Regen Clamp](http://r2r.tech/documentation/wiring-diagrams/scu6x-mxd-wiring-diagram-unwindrewind-actuator-without-regen-clamp.md)
- [SCU6x Product Brochure](http://r2r.tech/documentation/brochures/scu6x-product-brochure.md)
- [SCU6x Wiring with ODC Sensors](http://r2r.tech/documentation/wiring-diagrams/scu6x-wiring-odc-sensors.md)
- [SCU6x: 2D Drawing (pdf)](http://r2r.tech/documentation/2d-drawings/scu6x-2d-drawing-pdf.md)
- [SCU6x: 2D Drawing Front View (dxf)](http://r2r.tech/documentation/2d-drawings/scu6x-2d-drawing-front-view-dxf.md)
- [SCU6x: 2D Drawing SCUx Connectors (dxf)](http://r2r.tech/documentation/2d-drawings/scu6x-2d-drawing-scux-connectors-dxf.md)
- [SCU6x: Sensor and Web Guide Controller User Manual](http://r2r.tech/documentation/manuals/scu6x-sensor-and-web-guide-controller-user-manual.md)

---

# Web Guide Upgrade Kit

URL: https://r2r.tech/products/web-guides/web-guide-upgrade-kit.md

## Documentation


**Additional documentation:**
- [ARIS Retrofit Kit Product and User Manual](http://r2r.tech/documentation/manuals/aris-retrofit-kit-product-and-user-manual.md)
- [LHS-020-0xxx-RF: 2D Drawing (dxf)](http://r2r.tech/documentation/2d-drawings/lhs-020-0xxx-rf-2d-drawing-dxf.md)
- [LHS-020-0xxx-RF: 2D Drawing (pdf)](http://r2r.tech/documentation/2d-drawings/lhs-020-0xxx-rf-2d-drawing-pdf.md)
- [LHS-020-x400-TG](http://r2r.tech/documentation/2d-drawings/lhs-020-x400-tg.md)
- [Master/Slave Web Guiding System Installation](http://r2r.tech/documentation/manuals/masterslave-web-guiding-system-installation.md)
- [Motor Controller - MC QD 1140/1141/1240/1241: 2D Drawing](http://r2r.tech/documentation/2d-drawings/motor-controller-mc-qd-1140114112401241-2d-drawing.md)
- [Motor Controller - MC QD 1140/1141/1240/1241: 2D Drawing (DXF)](http://r2r.tech/documentation/2d-drawings/motor-controller-mc-qd-1140114112401241-2d-drawing-dxf.md)
- [Motor Controller - MC QD 1180/1181/1211/1230/1231/1260: 2D Drawing](http://r2r.tech/documentation/2d-drawings/motor-controller-mc-qd-118011811211123012311260-2d-drawing.md)
- [Motor Driver MC QD 1140/1141/1161/1180/1181/1211/1230/1231/1240/1260](http://r2r.tech/documentation/manuals/motor-driver-mc-qd-1140114111611180118112111230123112401260.md)
- [RTI + SCU5 MC(E)D Wiring with MC QD 1140/1141/1240 with Retrofit Actuator](http://r2r.tech/documentation/wiring-diagrams/rti-scu5-mced-wiring-mc-qd-114011411240-retrofit-actuator.md)
- [Retrofit Actuator - LHS-0xx-xxxx-TG: 2D Drawing (DXF)](http://r2r.tech/documentation/2d-drawings/retrofit-actuator-lhs-0xx-xxxx-tg-2d-drawing-dxf.md)
- [Retrofit Installation Checklist](http://r2r.tech/documentation/manuals/retrofit-installation-checklist.md)
- [Roll-2-Roll® Web Guide Upgrade Kit Product Brochure](http://r2r.tech/documentation/brochures/roll-2-rollr-web-guide-upgrade-kit-product-brochure.md)
- [SCU5 Controller: 2D Drawing (DXF)](http://r2r.tech/documentation/2d-drawings/scu5-controller-2d-drawing-dxf.md)
- [SCU5 Controller: 2D Drawing (pdf)](http://r2r.tech/documentation/2d-drawings/scu5-controller-2d-drawing-pdf.md)
- [SCU5 M: Web Guide Controller Product and User Manual (V2.6)](http://r2r.tech/documentation/manuals/scu5-m-web-guide-controller-product-and-user-manual-v26.md)
- [SCU5 MC(x)D Wiring with MC QD 1141/1140/1240 + Web Guide Actuator](http://r2r.tech/documentation/wiring-diagrams/scu5-mcxd-wiring-mc-qd-114111401240-web-guide-actuator.md)
- [SCU5 MD Wiring with MC QD 1141/1140/1240 + Web Guide Actuator](http://r2r.tech/documentation/wiring-diagrams/scu5-md-wiring-mc-qd-114111401240-web-guide-actuator.md)
- [SCU5 MD Wiring with MC QD 1180/1181/1211/1230/1231/1260 + Large Upgrade Actuator](http://r2r.tech/documentation/wiring-diagrams/scu5-md-wiring-mc-qd-118011811211123012311260-large-upgrade-actuator.md)
- [SCU5 MD Wiring with MC QD 1180/1181/1211/1230/1231/1260 + Regen Clamp + Unwind/Rewind Actuator](http://r2r.tech/documentation/wiring-diagrams/scu5-md-wiring-mc-qd-118011811211123012311260-regen-clamp.md)
- [SCU5 MD Wiring with MC QD 1180/1181/1211/1230/1231/1260 + Web Guide Actuator](http://r2r.tech/documentation/wiring-diagrams/scu5-md-wiring-mc-qd-118011811211123012311260-web-guide-actuator.md)
- [SCU5 MD Wiring with ODC Sensor, MC QD 1140/1141/1240 with Web Guide](http://r2r.tech/documentation/wiring-diagrams/scu5-md-wiring-odc-sensor-mc-qd-114011411240-web-guide.md)
- [SCU5 MDIO Wiring with MC QD 1141/1140/1240 + Web Guide Actuator](http://r2r.tech/documentation/wiring-diagrams/scu5-mdio-wiring-mc-qd-114111401240-web-guide-actuator.md)
- [SCU5: Sensor and Web Guide Controller User Manual v3.3](http://r2r.tech/documentation/manuals/scu5-sensor-and-web-guide-controller-user-manual-v33.md)
- [SCU5: Sensor and Web Guide Controller User Manual v3.4](http://r2r.tech/documentation/manuals/scu5-sensor-and-web-guide-controller-user-manual-v34.md)
- [Servo Center Servo Installation](http://r2r.tech/documentation/manuals/servo-center-servo-installation.md)
- [Standard Operating Procedure (SOP): Center Guiding Application (v2.x)](http://r2r.tech/documentation/manuals/standard-operating-procedure-sop-center-guiding-application-v2x.md)
- [Standard Operating Procedure (SOP): Edge Guiding Application (v2.x)](http://r2r.tech/documentation/manuals/standard-operating-procedure-sop-edge-guiding-application-v2x.md)
- [Standard Operating Procedure (SOP): Line Guiding Application](http://r2r.tech/documentation/manuals/standard-operating-procedure-sop-line-guiding-application.md)
- [Web Guide Upgrade or Retrofit Kit](http://r2r.tech/documentation/manuals/web-guide-upgrade-or-retrofit-kit.md)

---

# Wide Web Guides

URL: https://r2r.tech/products/web-guides/wide-web-guides.md

## Documentation

**3D Model (STEP):** [28in Web Guide Assembly -- Low Profile Web Guide](http://r2r.tech/documentation/3d-models/28in-web-guide-assembly-low-profile-web-guide.md)

**Additional documentation:**
- [ARIS SCU5 EtherNet/IP Configuration Manual](http://r2r.tech/documentation/manuals/aris-scu5-ethernetip-configuration-manual.md)
- [Case Study - Wide Web Guide System for Textiles](http://r2r.tech/documentation/case-studies/case-study-wide-web-guide-system-textiles.md)
- [Dimensional drawing of Wide Web Guides](http://r2r.tech/documentation/2d-drawings/dimensional-drawing-wide-web-guides.md)
- [Installation of Displacement Guide](http://r2r.tech/documentation/manuals/installation-displacement-guide.md)
- [Master/Slave Web Guiding System Installation](http://r2r.tech/documentation/manuals/masterslave-web-guiding-system-installation.md)
- [Motor Controller - MC QD 1140/1141/1240/1241: 2D Drawing](http://r2r.tech/documentation/2d-drawings/motor-controller-mc-qd-1140114112401241-2d-drawing.md)
- [Motor Controller - MC QD 1140/1141/1240/1241: 2D Drawing (DXF)](http://r2r.tech/documentation/2d-drawings/motor-controller-mc-qd-1140114112401241-2d-drawing-dxf.md)
- [Motor Controller - MC QD 1180/1181/1211/1230/1231/1260: 2D Drawing](http://r2r.tech/documentation/2d-drawings/motor-controller-mc-qd-118011811211123012311260-2d-drawing.md)
- [Motor Driver MC QD 1140/1141/1161/1180/1181/1211/1230/1231/1240/1260](http://r2r.tech/documentation/manuals/motor-driver-mc-qd-1140114111611180118112111230123112401260.md)
- [Roll-2-Roll® Web Guides: Product Brochure](http://r2r.tech/documentation/brochures/roll-2-rollr-web-guides-product-brochure.md)
- [SCU5 Controller: 2D Drawing (DXF)](http://r2r.tech/documentation/2d-drawings/scu5-controller-2d-drawing-dxf.md)
- [SCU5 Controller: 2D Drawing (pdf)](http://r2r.tech/documentation/2d-drawings/scu5-controller-2d-drawing-pdf.md)
- [SCU5 M: Web Guide Controller Product and User Manual (V2.6)](http://r2r.tech/documentation/manuals/scu5-m-web-guide-controller-product-and-user-manual-v26.md)
- [SCU5 MD Wiring with MC QD 1141/1140/1240 + Web Guide Actuator](http://r2r.tech/documentation/wiring-diagrams/scu5-md-wiring-mc-qd-114111401240-web-guide-actuator.md)
- [SCU5 MD Wiring with MC QD 1180/1181/1211/1230/1231/1260 + Web Guide Actuator](http://r2r.tech/documentation/wiring-diagrams/scu5-md-wiring-mc-qd-118011811211123012311260-web-guide-actuator.md)
- [SCU5 MD Wiring with ODC Sensor, MC QD 1140/1141/1240 with Web Guide](http://r2r.tech/documentation/wiring-diagrams/scu5-md-wiring-odc-sensor-mc-qd-114011411240-web-guide.md)
- [SCU5: Sensor and Web Guide Controller User Manual v3.3](http://r2r.tech/documentation/manuals/scu5-sensor-and-web-guide-controller-user-manual-v33.md)
- [SCU5: Sensor and Web Guide Controller User Manual v3.4](http://r2r.tech/documentation/manuals/scu5-sensor-and-web-guide-controller-user-manual-v34.md)
- [Servo Center Servo Installation](http://r2r.tech/documentation/manuals/servo-center-servo-installation.md)
- [Standard Operating Procedure (SOP): Center Guiding Application (v2.x)](http://r2r.tech/documentation/manuals/standard-operating-procedure-sop-center-guiding-application-v2x.md)
- [Standard Operating Procedure (SOP): Edge Guiding Application (v2.x)](http://r2r.tech/documentation/manuals/standard-operating-procedure-sop-edge-guiding-application-v2x.md)
- [Standard Operating Procedure (SOP): Line Guiding Application](http://r2r.tech/documentation/manuals/standard-operating-procedure-sop-line-guiding-application.md)
- [Web Guide Installation Checklist](http://r2r.tech/documentation/manuals/web-guide-installation-checklist.md)
- [Wide Web Guides Product Brochure](http://r2r.tech/documentation/brochures/wide-web-guides-product-brochure.md)
- [Wide Web Guides Product and User Manual](http://r2r.tech/documentation/manuals/wide-web-guides-product-and-user-manual.md)

---

# WPS 112

URL: https://r2r.tech/products/sensors/wps-112.md

## Documentation

**3D Model (STEP):** [1in Mounting Bracket for WPS and ODC Sensors](http://r2r.tech/documentation/3d-models/1in-mounting-bracket-wps-and-odc-sensors.md)

**Additional documentation:**
- [1.5in Mounting Bracket for WPS and ODC Sensors](http://r2r.tech/documentation/3d-models/15in-mounting-bracket-wps-and-odc-sensors.md)
- [Mounting Bracket for 1.5in or 40mm Extrusion for WPS, ODC and 1DC Sensors](http://r2r.tech/documentation/3d-models/mounting-bracket-15in-or-40mm-extrusion-wps-odc-and-1dc-sensors.md)
- [Mounting Bracket for 1in or 25mm Extrusion for WPS, ODC and 1DC Sensors](http://r2r.tech/documentation/3d-models/mounting-bracket-1in-or-25mm-extrusion-wps-odc-and-1dc-sensors.md)
- [New Mounting Brackets for WPS, ODC and 1DC sensors - 1.5 in or 40 mm extrusion](http://r2r.tech/documentation/2d-drawings/new-mounting-brackets-wps-odc-and-1dc-sensors-15-or-40-mm-extrusion.md)
- [New Mounting Brackets for WPS, ODC and 1DC sensors - 1in or 25 mm extrusion](http://r2r.tech/documentation/2d-drawings/new-mounting-brackets-wps-odc-and-1dc-sensors-1in-or-25-mm-extrusion.md)
- [ODC and WPS Installation for Center Guiding and Web Width Measurement](http://r2r.tech/documentation/manuals/odc-and-wps-installation-center-guiding-and-web-width-measurement.md)
- [Roll-2-Roll® Sensor: WPS Product Brochure](http://r2r.tech/documentation/brochures/roll-2-rollr-sensor-wps-product-brochure.md)
- [SCU5 C(x)D Wiring with WPS Sensor (Industrial Ethernet)](http://r2r.tech/documentation/wiring-diagrams/scu5-cxd-wiring-wps-sensor-industrial-ethernet.md)
- [SCU5 D Wiring with WPS Sensor (Analog Output)](http://r2r.tech/documentation/wiring-diagrams/scu5-d-wiring-wps-sensor-analog-output.md)
- [SCU5 DD Wiring with WPS Sensor (Digital Output)](http://r2r.tech/documentation/wiring-diagrams/scu5-dd-wiring-wps-sensor-digital-output.md)
- [SCU5 DI Wiring with WPS Sensor (Digital Input and Output)](http://r2r.tech/documentation/wiring-diagrams/scu5-di-wiring-wps-sensor-digital-input-and-output.md)
- [Sensor Installation Recommendations: Inspection Applications](http://r2r.tech/documentation/manuals/sensor-installation-recommendations-inspection-applications.md)
- [WPS 112 with Standard Mounting Brackets: 2D Drawing (pdf)](http://r2r.tech/documentation/2d-drawings/wps-112-standard-mounting-brackets-2d-drawing-pdf.md)
- [WPS 112-xx QD](http://r2r.tech/documentation/3d-models/wps-112-xx-qd.md)
- [WPS 112/221/440/900 or ODC 96/192/288/384/480/768/960 Sensor Installation for to Reduce the Effect of Twist](http://r2r.tech/documentation/manuals/wps-112221440900-or-odc-96192288384480768960-sensor-installation-reduce.md)

---

# WPS 221

URL: https://r2r.tech/sensors/wps-221.md

## Documentation

**3D Model (STEP):** [1in Mounting Bracket for WPS and ODC Sensors](http://r2r.tech/documentation/3d-models/1in-mounting-bracket-wps-and-odc-sensors.md)

**Additional documentation:**
- [1.5in Mounting Bracket for WPS and ODC Sensors](http://r2r.tech/documentation/3d-models/15in-mounting-bracket-wps-and-odc-sensors.md)
- [ARIS Web Position Sensor Product Manual](http://r2r.tech/documentation/manuals/aris-web-position-sensor-product-manual.md)
- [Material Agnostic Fiber Optic Web Edge Sensor](http://r2r.tech/documentation/white-papers/material-agnostic-fiber-optic-web-edge-sensor.md)
- [Mounting Bracket for 1.5in or 40mm Extrusion for WPS, ODC and 1DC Sensors](http://r2r.tech/documentation/3d-models/mounting-bracket-15in-or-40mm-extrusion-wps-odc-and-1dc-sensors.md)
- [Mounting Bracket for 1in or 25mm Extrusion for WPS, ODC and 1DC Sensors](http://r2r.tech/documentation/3d-models/mounting-bracket-1in-or-25mm-extrusion-wps-odc-and-1dc-sensors.md)
- [New Mounting Brackets for WPS, ODC and 1DC sensors - 1.5 in or 40 mm extrusion](http://r2r.tech/documentation/2d-drawings/new-mounting-brackets-wps-odc-and-1dc-sensors-15-or-40-mm-extrusion.md)
- [New Mounting Brackets for WPS, ODC and 1DC sensors - 1in or 25 mm extrusion](http://r2r.tech/documentation/2d-drawings/new-mounting-brackets-wps-odc-and-1dc-sensors-1in-or-25-mm-extrusion.md)
- [ODC and WPS Installation for Center Guiding and Web Width Measurement](http://r2r.tech/documentation/manuals/odc-and-wps-installation-center-guiding-and-web-width-measurement.md)
- [Roll-2-Roll® Sensor: WPS Product Brochure](http://r2r.tech/documentation/brochures/roll-2-rollr-sensor-wps-product-brochure.md)
- [SCU5 C(x)D Wiring with WPS Sensor (Industrial Ethernet)](http://r2r.tech/documentation/wiring-diagrams/scu5-cxd-wiring-wps-sensor-industrial-ethernet.md)
- [SCU5 D Wiring with WPS Sensor (Analog Output)](http://r2r.tech/documentation/wiring-diagrams/scu5-d-wiring-wps-sensor-analog-output.md)
- [SCU5 DD Wiring with WPS Sensor (Digital Output)](http://r2r.tech/documentation/wiring-diagrams/scu5-dd-wiring-wps-sensor-digital-output.md)
- [SCU5 DI Wiring with WPS Sensor (Digital Input and Output)](http://r2r.tech/documentation/wiring-diagrams/scu5-di-wiring-wps-sensor-digital-input-and-output.md)
- [Sensor Installation Recommendations](http://r2r.tech/documentation/manuals/sensor-installation-recommendations.md)
- [Sensor Installation Recommendations: Inspection Applications](http://r2r.tech/documentation/manuals/sensor-installation-recommendations-inspection-applications.md)
- [WPS 112/221/440/900 or ODC 96/192/288/384/480/768/960 Sensor Installation for to Reduce the Effect of Twist](http://r2r.tech/documentation/manuals/wps-112221440900-or-odc-96192288384480768960-sensor-installation-reduce.md)
- [WPS 221 xx-QD](http://r2r.tech/documentation/2d-drawings/wps-221-xx-qd.md)
- [WPS 221-xx QD](http://r2r.tech/documentation/3d-models/wps-221-xx-qd.md)
- [Web Guide: Disturbance Rejection Performance](http://r2r.tech/documentation/white-papers/web-guide-disturbance-rejection-performance.md)
- [Web Guides: Dynamic Performance with High Speed Actuator](http://r2r.tech/documentation/white-papers/web-guides-dynamic-performance-high-speed-actuator.md)
- [Web Guides: How to Quantify the Dynamic Performance?](http://r2r.tech/documentation/white-papers/web-guides-how-quantify-dynamic-performance.md)

---

# WPS 440

URL: https://r2r.tech/products/sensors/wps-440.md

## Documentation

**3D Model (STEP):** [1in Mounting Bracket for WPS and ODC Sensors](http://r2r.tech/documentation/3d-models/1in-mounting-bracket-wps-and-odc-sensors.md)

**Additional documentation:**
- [1.5in Mounting Bracket for WPS and ODC Sensors](http://r2r.tech/documentation/3d-models/15in-mounting-bracket-wps-and-odc-sensors.md)
- [ARIS WPS 440 Product Manual (Generic Version)](http://r2r.tech/documentation/manuals/aris-wps-440-product-manual-generic-version.md)
- [Material Agnostic Fiber Optic Web Edge Sensor](http://r2r.tech/documentation/white-papers/material-agnostic-fiber-optic-web-edge-sensor.md)
- [Mounting Bracket for 1.5in or 40mm Extrusion for WPS, ODC and 1DC Sensors](http://r2r.tech/documentation/3d-models/mounting-bracket-15in-or-40mm-extrusion-wps-odc-and-1dc-sensors.md)
- [Mounting Bracket for 1in or 25mm Extrusion for WPS, ODC and 1DC Sensors](http://r2r.tech/documentation/3d-models/mounting-bracket-1in-or-25mm-extrusion-wps-odc-and-1dc-sensors.md)
- [New Mounting Brackets for WPS, ODC and 1DC sensors - 1.5 in or 40 mm extrusion](http://r2r.tech/documentation/2d-drawings/new-mounting-brackets-wps-odc-and-1dc-sensors-15-or-40-mm-extrusion.md)
- [New Mounting Brackets for WPS, ODC and 1DC sensors - 1in or 25 mm extrusion](http://r2r.tech/documentation/2d-drawings/new-mounting-brackets-wps-odc-and-1dc-sensors-1in-or-25-mm-extrusion.md)
- [ODC and WPS Installation for Center Guiding and Web Width Measurement](http://r2r.tech/documentation/manuals/odc-and-wps-installation-center-guiding-and-web-width-measurement.md)
- [Roll-2-Roll® Sensor: WPS 440 Product Brochure](http://r2r.tech/documentation/brochures/roll-2-rollr-sensor-wps-440-product-brochure.md)
- [Roll-2-Roll® Sensor: WPS Product Brochure](http://r2r.tech/documentation/brochures/roll-2-rollr-sensor-wps-product-brochure.md)
- [SCU5 C(x)D Wiring with WPS Sensor (Industrial Ethernet)](http://r2r.tech/documentation/wiring-diagrams/scu5-cxd-wiring-wps-sensor-industrial-ethernet.md)
- [SCU5 D Wiring with WPS Sensor (Analog Output)](http://r2r.tech/documentation/wiring-diagrams/scu5-d-wiring-wps-sensor-analog-output.md)
- [SCU5 DD Wiring with WPS Sensor (Digital Output)](http://r2r.tech/documentation/wiring-diagrams/scu5-dd-wiring-wps-sensor-digital-output.md)
- [SCU5 DI Wiring with WPS Sensor (Digital Input and Output)](http://r2r.tech/documentation/wiring-diagrams/scu5-di-wiring-wps-sensor-digital-input-and-output.md)
- [Sensor Installation Recommendations](http://r2r.tech/documentation/manuals/sensor-installation-recommendations.md)
- [Sensor Installation Recommendations: Inspection Applications](http://r2r.tech/documentation/manuals/sensor-installation-recommendations-inspection-applications.md)
- [WPS 112/221/440/900 or ODC 96/192/288/384/480/768/960 Sensor Installation for to Reduce the Effect of Twist](http://r2r.tech/documentation/manuals/wps-112221440900-or-odc-96192288384480768960-sensor-installation-reduce.md)
- [WPS 440 xx-QD](http://r2r.tech/documentation/2d-drawings/wps-440-xx-qd.md)
- [WPS 440-xx QD](http://r2r.tech/documentation/3d-models/wps-440-xx-qd.md)
- [WPS 440-xx QD Pixel Location: 2D Drawing](http://r2r.tech/documentation/2d-drawings/wps-440-xx-qd-pixel-location-2d-drawing.md)

---

# WPS 48

URL: https://r2r.tech/products/sensors/wps-48.md

## Documentation

**3D Model (STEP):** [1in Mounting Bracket for WPS and ODC Sensors](http://r2r.tech/documentation/3d-models/1in-mounting-bracket-wps-and-odc-sensors.md)

**Additional documentation:**
- [1.5in Mounting Bracket for WPS and ODC Sensors](http://r2r.tech/documentation/3d-models/15in-mounting-bracket-wps-and-odc-sensors.md)
- [ARIS Web Position Sensor Product Manual](http://r2r.tech/documentation/manuals/aris-web-position-sensor-product-manual.md)
- [CASE STUDY: Pneumo-hydraulic Web Guide Upgrade of a GWD Web Guide MA 2200](http://r2r.tech/documentation/case-studies/case-study-pneumo-hydraulic-web-guide-upgrade-gwd-web-guide-ma-2200.md)
- [CASE STUDY: Web Guide Sensor Upgrade - Metal Lamination](http://r2r.tech/documentation/case-studies/case-study-web-guide-sensor-upgrade-metal-lamination.md)
- [CASE STUDY: Web Guide Upgrade Kit for Aging Web Guides](http://r2r.tech/documentation/case-studies/case-study-web-guide-upgrade-kit-aging-web-guides.md)
- [Case Study - Line Guiding Application](http://r2r.tech/documentation/case-studies/case-study-line-guiding-application.md)
- [Case Study - Pneumo-hydraulic North American Web Guide Upgrade](http://r2r.tech/documentation/case-studies/case-study-pneumo-hydraulic-north-american-web-guide-upgrade.md)
- [Case Study - Uneven Edge Guiding - Specialty Sensing](http://r2r.tech/documentation/case-studies/case-study-uneven-edge-guiding-specialty-sensing.md)
- [Case Study - Wide Web Guide System for Textiles](http://r2r.tech/documentation/case-studies/case-study-wide-web-guide-system-textiles.md)
- [Mounting Bracket for 1.5in or 40mm Extrusion for WPS, ODC and 1DC Sensors](http://r2r.tech/documentation/3d-models/mounting-bracket-15in-or-40mm-extrusion-wps-odc-and-1dc-sensors.md)
- [Mounting Bracket for 1in or 25mm Extrusion for WPS, ODC and 1DC Sensors](http://r2r.tech/documentation/3d-models/mounting-bracket-1in-or-25mm-extrusion-wps-odc-and-1dc-sensors.md)
- [New Mounting Brackets for WPS, ODC and 1DC sensors - 1.5 in or 40 mm extrusion](http://r2r.tech/documentation/2d-drawings/new-mounting-brackets-wps-odc-and-1dc-sensors-15-or-40-mm-extrusion.md)
- [New Mounting Brackets for WPS, ODC and 1DC sensors - 1in or 25 mm extrusion](http://r2r.tech/documentation/2d-drawings/new-mounting-brackets-wps-odc-and-1dc-sensors-1in-or-25-mm-extrusion.md)
- [Roll-2-Roll® Sensor: WPS Product Brochure](http://r2r.tech/documentation/brochures/roll-2-rollr-sensor-wps-product-brochure.md)
- [SCU5 C(x)D Wiring with WPS Sensor (Industrial Ethernet)](http://r2r.tech/documentation/wiring-diagrams/scu5-cxd-wiring-wps-sensor-industrial-ethernet.md)
- [SCU5 D Wiring with WPS Sensor (Analog Output)](http://r2r.tech/documentation/wiring-diagrams/scu5-d-wiring-wps-sensor-analog-output.md)
- [SCU5 DD Wiring with WPS Sensor (Digital Output)](http://r2r.tech/documentation/wiring-diagrams/scu5-dd-wiring-wps-sensor-digital-output.md)
- [SCU5 DI Wiring with WPS Sensor (Digital Input and Output)](http://r2r.tech/documentation/wiring-diagrams/scu5-di-wiring-wps-sensor-digital-input-and-output.md)
- [Sensor Installation Recommendations](http://r2r.tech/documentation/manuals/sensor-installation-recommendations.md)
- [Sensor Installation Recommendations: Inspection Applications](http://r2r.tech/documentation/manuals/sensor-installation-recommendations-inspection-applications.md)
- [Sensor for Line Guiding and Contrast Guiding Applications](http://r2r.tech/documentation/white-papers/sensor-line-guiding-and-contrast-guiding-applications.md)
- [WPS 48-xx QD (1" Mounting)](http://r2r.tech/documentation/3d-models/wps-48-xx-qd-1-mounting.md)
- [WPS 48-xx QD (NW Rail)](http://r2r.tech/documentation/3d-models/wps-48-xx-qd-nw-rail.md)
- [WPS 48-xx QD (No Mounting Bracket)](http://r2r.tech/documentation/3d-models/wps-48-xx-qd-no-mounting-bracket.md)
- [WPS 48-xx QD: 2D Drawing (pdf)](http://r2r.tech/documentation/2d-drawings/wps-48-xx-qd-2d-drawing-pdf.md)
- [WPS 48: 2D Drawing (DXF)](http://r2r.tech/documentation/2d-drawings/wps-48-2d-drawing-dxf.md)

---

# WPS 900

URL: https://r2r.tech/sensors/wps-900.md

## Documentation

**3D Model (STEP):** [1in Mounting Bracket for WPS and ODC Sensors](http://r2r.tech/documentation/3d-models/1in-mounting-bracket-wps-and-odc-sensors.md)

**Additional documentation:**
- [1.5in Mounting Bracket for WPS and ODC Sensors](http://r2r.tech/documentation/3d-models/15in-mounting-bracket-wps-and-odc-sensors.md)
- [Mounting Bracket for 1.5in or 40mm Extrusion for WPS, ODC and 1DC Sensors](http://r2r.tech/documentation/3d-models/mounting-bracket-15in-or-40mm-extrusion-wps-odc-and-1dc-sensors.md)
- [Mounting Bracket for 1in or 25mm Extrusion for WPS, ODC and 1DC Sensors](http://r2r.tech/documentation/3d-models/mounting-bracket-1in-or-25mm-extrusion-wps-odc-and-1dc-sensors.md)
- [New Mounting Brackets for WPS, ODC and 1DC sensors - 1.5 in or 40 mm extrusion](http://r2r.tech/documentation/2d-drawings/new-mounting-brackets-wps-odc-and-1dc-sensors-15-or-40-mm-extrusion.md)
- [New Mounting Brackets for WPS, ODC and 1DC sensors - 1in or 25 mm extrusion](http://r2r.tech/documentation/2d-drawings/new-mounting-brackets-wps-odc-and-1dc-sensors-1in-or-25-mm-extrusion.md)
- [ODC and WPS Installation for Center Guiding and Web Width Measurement](http://r2r.tech/documentation/manuals/odc-and-wps-installation-center-guiding-and-web-width-measurement.md)
- [Roll-2-Roll® Sensor: WPS 900 Product Brochure](http://r2r.tech/documentation/wps-900-product-brochure.md)
- [Roll-2-Roll® Sensor: WPS Product Brochure](http://r2r.tech/documentation/brochures/roll-2-rollr-sensor-wps-product-brochure.md)
- [Sensor Installation Recommendations: Inspection Applications](http://r2r.tech/documentation/manuals/sensor-installation-recommendations-inspection-applications.md)
- [WPS 112/221/440/900 or ODC 96/192/288/384/480/768/960 Sensor Installation for to Reduce the Effect of Twist](http://r2r.tech/documentation/manuals/wps-112221440900-or-odc-96192288384480768960-sensor-installation-reduce.md)
- [WPS 900-xx QD](http://r2r.tech/documentation/3d-models/wps-900-xx-qd.md)

---

# Splice Detection — Industrial Ethernet — 1DC Series

URL: https://r2r.tech/resources/quick-start/splice-detection/ethernet/1dc.md

URL: https://r2r.tech/resources/quick-start/splice-detection/ethernet/1dc.md

Step-by-step installation & configuration guide. PDF at https://r2r.tech/resources/quick-start/splice-detection/ethernet/1dc.pdf.

---

# Splice Detection — Industrial Ethernet — SCU6x

URL: https://r2r.tech/resources/quick-start/splice-detection/ethernet/scu6x.md

URL: https://r2r.tech/resources/quick-start/splice-detection/ethernet/scu6x.md

Step-by-step installation & configuration guide. PDF at https://r2r.tech/resources/quick-start/splice-detection/ethernet/scu6x.pdf.

---

# Splice Detection — Digital Output — SCU6x

URL: https://r2r.tech/resources/quick-start/splice-detection/digital/scu6x.md

URL: https://r2r.tech/resources/quick-start/splice-detection/digital/scu6x.md

Step-by-step installation & configuration guide. PDF at https://r2r.tech/resources/quick-start/splice-detection/digital/scu6x.pdf.

---

# Position Measurement — Analog Output — SCU5

URL: https://r2r.tech/resources/quick-start/position-measurement/analog/scu5.md

URL: https://r2r.tech/resources/quick-start/position-measurement/analog/scu5.md

Step-by-step installation & configuration guide. PDF at https://r2r.tech/resources/quick-start/position-measurement/analog/scu5.pdf.

---

# Position Measurement — Industrial Ethernet — SCU5

URL: https://r2r.tech/resources/quick-start/position-measurement/ethernet/scu5.md

URL: https://r2r.tech/resources/quick-start/position-measurement/ethernet/scu5.md

Step-by-step installation & configuration guide. PDF at https://r2r.tech/resources/quick-start/position-measurement/ethernet/scu5.pdf.

---

# Position Measurement — Industrial Ethernet — SCU6x

URL: https://r2r.tech/resources/quick-start/position-measurement/ethernet/scu6x.md

URL: https://r2r.tech/resources/quick-start/position-measurement/ethernet/scu6x.md

Step-by-step installation & configuration guide. PDF at https://r2r.tech/resources/quick-start/position-measurement/ethernet/scu6x.pdf.

---

# Position Measurement — Industrial Ethernet — 1DC Series

URL: https://r2r.tech/resources/quick-start/position-measurement/ethernet/1dc.md

URL: https://r2r.tech/resources/quick-start/position-measurement/ethernet/1dc.md

Step-by-step installation & configuration guide. PDF at https://r2r.tech/resources/quick-start/position-measurement/ethernet/1dc.pdf.

---

# Web Width Measurement — Analog Output — SCU5

URL: https://r2r.tech/resources/quick-start/web-width/analog/scu5.md

URL: https://r2r.tech/resources/quick-start/web-width/analog/scu5.md

Step-by-step installation & configuration guide. PDF at https://r2r.tech/resources/quick-start/web-width/analog/scu5.pdf.

---

# Web Width Measurement — Digital Monitoring — SCU5

URL: https://r2r.tech/resources/quick-start/web-width/digital/scu5.md

URL: https://r2r.tech/resources/quick-start/web-width/digital/scu5.md

Step-by-step installation & configuration guide. PDF at https://r2r.tech/resources/quick-start/web-width/digital/scu5.pdf.

---

# Web Width Measurement — Industrial Ethernet — SCU5

URL: https://r2r.tech/resources/quick-start/web-width/ethernet/scu5.md

URL: https://r2r.tech/resources/quick-start/web-width/ethernet/scu5.md

Step-by-step installation & configuration guide. PDF at https://r2r.tech/resources/quick-start/web-width/ethernet/scu5.pdf.

---

# Web Width Measurement — Digital Monitoring — SCU6x

URL: https://r2r.tech/resources/quick-start/web-width/digital/scu6x.md

URL: https://r2r.tech/resources/quick-start/web-width/digital/scu6x.md

Step-by-step installation & configuration guide. PDF at https://r2r.tech/resources/quick-start/web-width/digital/scu6x.pdf.

---

# Web Width Measurement — Industrial Ethernet — SCU6x

URL: https://r2r.tech/resources/quick-start/web-width/ethernet/scu6x.md

URL: https://r2r.tech/resources/quick-start/web-width/ethernet/scu6x.md

Step-by-step installation & configuration guide. PDF at https://r2r.tech/resources/quick-start/web-width/ethernet/scu6x.pdf.

---

# Web Width Measurement — Industrial Ethernet — 1DC Series

URL: https://r2r.tech/resources/quick-start/web-width/ethernet/1dc.md

URL: https://r2r.tech/resources/quick-start/web-width/ethernet/1dc.md

Step-by-step installation & configuration guide. PDF at https://r2r.tech/resources/quick-start/web-width/ethernet/1dc.pdf.

---

# Multiple Web Width Measurement — Industrial Ethernet — SCU6x

URL: https://r2r.tech/resources/quick-start/multi-web-width/ethernet/scu6x.md

URL: https://r2r.tech/resources/quick-start/multi-web-width/ethernet/scu6x.md

Step-by-step installation & configuration guide. PDF at https://r2r.tech/resources/quick-start/multi-web-width/ethernet/scu6x.pdf.

---

# Multiple Web Width Measurement — Digital Monitoring — SCU6x

URL: https://r2r.tech/resources/quick-start/multi-web-width/digital/scu6x.md

URL: https://r2r.tech/resources/quick-start/multi-web-width/digital/scu6x.md

Step-by-step installation & configuration guide. PDF at https://r2r.tech/resources/quick-start/multi-web-width/digital/scu6x.pdf.

---

# Multiple Web Width Measurement — Industrial Ethernet — 1DC Series

URL: https://r2r.tech/resources/quick-start/multi-web-width/ethernet/1dc.md

URL: https://r2r.tech/resources/quick-start/multi-web-width/ethernet/1dc.md

Step-by-step installation & configuration guide. PDF at https://r2r.tech/resources/quick-start/multi-web-width/ethernet/1dc.pdf.

---

# Quick Start Guides JSON API

URL: https://r2r.tech/api/v1/quick-start-guides

URL: https://r2r.tech/api/v1/quick-start-guides

JSON index of all active Quick Start Guides. Ask the customer their application + controller + output type, then return the matching guide URL.

---

# Battery Manufacturing

URL: https://r2r.tech/industries/battery-manufacturing.md

## Overview



Roll-2-Roll Technologies provides advanced sensor solutions designed for the spatial constraints and precision requirements of modern battery manufacturing. As the industry moves toward wider webs and faster line speeds to reduce cell costs, precision becomes critical. Our **one-sided, integrated sensor design** combines light source, optics, and camera into a single compact unit—eliminating the need for bulky external gantries while delivering **0.016 mm resolution**. **No programming is needed**—operators can set up the system in minutes, reducing engineering overhead and total cost of ownership.




## The Engineering Challenge



Battery manufacturing lines involve harsh environments and extreme precision requirements that defeat traditional sensing methods.



- Spatial Constraints: Critical measurement points inside drying ovens or immediately before calender presses are notoriously tight. Traditional C-frame sensors simply do not fit.
- Electrode Misalignment: Anode and cathode coatings must overlap with extreme precision. Drifting by even a fraction of a millimeter can cause lithium plating or short circuits.
- "Lost Edge" Stops: Heavy battery foils wander during splices or speed ramps. Narrow-view sensors lose the edge, triggering costly machine E-stops.
- Calendering Damage: If the web enters the high-pressure calender nip slightly skewed, wrinkles are pressed into the electrode, destroying the material.




## The R2R Technical Advantage



We address these challenges with a unique architectural approach that prioritizes accessibility and performance. Effectively, you get a **Vision System in a Sensor Package**.



- Line Scan Camera Technology: While marketed as a sensor, the device functions as a one-dimensional line scan camera with a pixel array ranging from 768 to over 14,000 pixels. This provides the "spatial awareness" to see multiple edges and features simultaneously.
- Linear Optical Technology: Unlike traditional cameras with circular lenses that cause distortion, our patented fiber optic array provides 1:1 image magnification. This ensures measurement accuracy is identical across the entire field of view.
- Compact, One-Sided Installation: Our sensors operate from a single side of the web, allowing installation in restricted areas (typically around 10-15 mm from the web) where traditional frames won't fit.
- Wide Viewing Area: We offer a significantly wider viewing area (up to 960mm) compared to standard sensors, ensuring continuous tracking even when the web wanders significantly during process upsets.
- Sub-Pixel Precision: Proprietary algorithms push effective resolution to 0.016 mm, critical for holding tight coating tolerances.




## Key Applications




### 1. Electrode Coating Alignment & Width Measurement



Ensure precise overlay of anode/cathode coating on current collectors. The **wide viewing area** allows for real-time monitoring of both the coating edge position and the total coating width. The sensors use **contrast detection** to measure the distance between the edge of the metal foil and the edge of the active material coating, ensuring the coating is properly centered and applied.




### 2. Calender Infeed Guiding



Space is at a premium near high-pressure calender rolls. Our **compact, one-sided sensors** can be mounted immediately adjacent to the nip point. This proximity reduces "dead time" (transport lag), providing the web guide with real-time data to correct high-frequency disturbances before wrinkles occur.




### 3. Trim and Tab Measurement



The system can simultaneously measure multiple specific widths, such as "trim one width," "trim two coating width," and "tab width." In the slitting and notching phase, accurately measuring these dimensions is critical for quality control. R2R's high-resolution sensors provide the precision needed to verify tab tolerances in real-time.




### 4. Electrode Slitting



Accurate width measurement is used during the slitting of anode and cathode materials to ensure precise dimensions before cell assembly. With **0.016 mm resolution**, operators can detect even minor width variations immediately, ensuring consistency across the entire roll.




### 5. Oven-Internal Monitoring



Unlike bulky thru-beam frames, the R2R sensor can be mounted inside the drying oven environment (with appropriate cooling/shielding) to monitor web stability during the critical drying phase, preventing coating defects caused by flutter.




## Supported Web Guiding Solutions



Our controllers come pre-loaded with multiple guiding software modules, allowing one system to adapt to various battery production needs.



- Center Guiding: Uses two sensors to track both edges of the anode or cathode foil, keeping the centerline perfectly aligned during coating or calendering. Essential for maintaining symmetry on varying width foils.
- Edge Guiding: The most common application. Uses a single sensor to track the foil edge or coating edge for precise positioning entering the dryer or slitter.
- Master-Slave Guiding: Critical for lamination. One web (the master) is tracked, and the second web (the slave) is guided to align perfectly with it, ensuring accurate anode-cathode overlap.




## Digital Integration & Connectivity



Our controllers support major industrial protocols like **EtherNet/IP, PROFINET, and EtherCAT**, enabling seamless integration with battery line PLCs for automated control. The system also offers app-based data logging, allowing quality assurance teams to download width and position logs to CSV files for batch validation.




## Technical Comparison



**The "Scanner vs. Laser Pointer" Analogy:** Comparing an R2R Sensor to a standard photo-eye is like comparing a flatbed scanner to a laser pointer. A laser pointer only tells you if something is blocking a specific spot (on/off). An R2R sensor "scans" the entire edge profile, allowing it to understand exactly what is there (foil edge, coating edge, or defect) and where it is.



- Installation: Traditional optical sensors require two-sided frames. R2R uses a one-sided, compact mount suitable for tight battery lines.
- Sensing Window: Standard sensors have a narrow window (10-20mm). R2R provides a Wide Viewing Area (up to 960mm) to prevent lost-edge stops.
- Resolution: Pixel-limited sensors struggle with microns. R2R achieves 0.016 mm Sub-pixel resolution.
- Components: Instead of separate emitters and receivers, R2R offers an All-in-One Integrated unit with lower TCO.

---

# Converting & Flexible Packaging

URL: https://r2r.tech/industries/converting-flexible-packaging.md

## Overview



The converting industry is defined by "High-Mix, Low-Volume" production. Converters constantly switch between materials—clear poly films one hour, opaque paper the next, and reflective foils after that. Roll-2-Roll Technologies delivers **One Sensor for Any Material**—a sensing solution that eliminates the need for sensor recalibration during changeovers. **No programming is needed**, and the "Plug-and-Play" orientation makes it easy for any operator to run, significantly lowering the **total cost of ownership**.




## The Engineering Challenge



Frequent job changes and diverse materials create bottlenecks for traditional sensor technologies.



- The "Clear Film" Challenge: As packaging moves toward "no-label look" transparent films, traditional optical sensors fail because the beam passes through. Ultrasonic sensors work but are sensitive to air turbulence and temperature fluctuations.
- Setup Time Fatigue: Operators must manually recalibrate sensors (gain, contrast) for each new material. This takes time and introduces human error.
- Splice Failure: Detecting splices (especially clear-on-clear) is critical to protect downstream quality, but notoriously difficult for standard photo-eyes.




## The R2R Technical Advantage



Our patented fiber-optic technology offers the capabilities of a **Vision System in a Sensor Package** without the complexity.



- Material-Independent Physics: We rely on light scattering, not blocking. Every material—clear, opaque, or reflective—scatters light. The sensor detects this signature automatically without calibration.
- Linear Optical Technology: Our fiber optic array provides 1:1 image magnification without distortion, ensuring accurate edge detection regardless of web position.
- Zero Recalibration: Switch from opaque foil to clear film without touching the sensor. It works instantly, significantly reducing changeover downtime.
- Environmental Robustness: Unlike ultrasonic sensors, our fiber-optic solution is immune to the acoustic noise, air turbulence, and vacuum environments found in high-speed converting.
- Operational Simplicity: Simple "teach" functions and an intuitive interface mean no "expert" is required for setup.




## Key Applications




### 1. Splice, Defect, and Flag Detection



The sensor possesses **spatial awareness** to detect various types of splices (including difficult-to-see transparent and butt splices), tears, and holes at high speeds (up to 1,000 ft/min). It can also detect flags used to mark defects on a web, triggering downstream equipment to reject that section automatically.




### 2. Universal Web Guiding for High-Mix Runs



For converters running various material widths, the wide sensor eliminates the need to mechanically reposition sensors during job changeovers. Guide clear film, opaque paper, and reflective foil without parameter changes using "Plug-and-Play" capability.




### 3. Automated Blade Positioning Verification



In slitting lines, the sensor verifies that the blades are set correctly by measuring the slit widths in real-time. This eliminates operator error associated with manual tape measurements and ensures strict tolerance adherence.




### 4. High-Speed Slitting



In slitting rewinding, web width often varies slightly. R2R's **Wide Viewing Area** ensures the sensor never loses the edge, even if the web oscillates or width changes during the run, preventing machine stops. A single sensor can even track multiple slit webs simultaneously.




## Supported Web Guiding Solutions



From the unwind to the rewind, R2R provides comprehensive control for the converting process.



- Unwind & Rewind Guiding: Controls the lateral position of the unwind or rewind stand to ensure the web enters the process aligned and winds up with a straight edge. Essential for preventing telescoping rolls.
- Edge Guiding: The standard for most converting applications. Keeps the web aligned to a fixed point for printing, coating, or laminating.
- Center Guiding: Automatically calculates the web's center using two sensors. Perfect for converting runs where material width varies (e.g., different job sizes) to keep the web centered in the machine.
- Web Oscillation: Deliberately oscillates the web or winder to distribute gauge bands (thickness variations) evenly across the roll, preventing star patterns and hard spots.




## Technical Comparison



**The "Scanner vs. Laser Pointer" Analogy:** Comparing an R2R Sensor to a standard photo-eye is like comparing a flatbed scanner to a laser pointer. A standard sensor only knows if the beam is blocked. An R2R sensor (scanner) sees the entire "picture" of the web edge. This allows it to distinguish between a real edge and a transparent film layer, ensuring reliable guiding where simple photo-eyes fail.



- Material Handling: Competitors require selecting Infrared vs. Ultrasonic sensors. R2R is Material-Independent (one sensor for all).
- Calibration: Traditional systems require "Teach Mode" for every job. R2R requires No Calibration.
- Cost Effectiveness: Eliminates the need for separate vision systems or multiple sensor types.
- Ease of Use: No complex menus or "Catalog Labyrinth." Just simple, reliable sensing.

---

# Film Extrusion

URL: https://r2r.tech/industries/film-extrusion.md

## Overview

Film extrusion (Blown and Cast) is a continuous, 24/7 process where stability is paramount. [Roll-2-Roll® Sensors](https://r2r.tech/products/sensors) provide non-contact precision to measure and align the web without damaging the delicate product. With **no programming needed** and a robust design, [Roll-2-Roll® Controllers](https://r2r.tech/products/controllers) offer a lower total cost of ownership by replacing complex, maintenance-heavy mechanical tracking systems with **advanced vision system capabilities**.

## The Engineering Challenge

Maintaining gauge consistency and dimensional accuracy in extrusion presents unique physical challenges.

- Layflat Variation (Blown Film): In blown film, the "bubble" diameter fluctuates due to air pressure changes. Manual measurement with a tape is dangerous and inaccurate.
- Neck-In Control (Cast Film): As molten plastic leaves the die, it narrows (necks in). Accurately tracking this wandering, molten edge to minimize edge bead trim is difficult for contact or narrow optical sensors.
- Oscillating Haul-Offs: To randomize gauge variations, the haul-off unit oscillates. Web guides must track this movement perfectly; narrow sensors often lose the edge at turnaround points.

## The Roll-2-Roll Technical Advantage

Our wide-area sensing technology brings **operational simplicity** and precision to the extrusion line.

- Wide Viewing Area: With a sensing window up to 960mm, [Roll-2-Roll® Sensors](https://r2r.tech/products/sensors) track the full range of oscillating webs without needing complex motorized "chaser" bases. This eliminates expensive moving parts.
- Linear Optical Technology: The 1:1 magnification of our fiber optic array ensures that width measurements are accurate across the entire sensor range, free from the lens distortion common in camera systems.
- 0.0635 mm Resolution: High-precision edge detection and guiding allows for minimal trim waste, directly saving resin costs.
- Non-Contact Safety: One-sided, non-contact measurement keeps operators safe and prevents marking on hot, soft films.
- Modularity: Controllers and sensors are interchangeable; a sensor used for guiding can be repurposed for width measurement.

## Key Applications

### 1. Blown Film Layflat Measurement

In blown film lines, the sensors measure the "layflat" width of the tube to ensure the internal bubble cooling (IBC) and process parameters are correct. This data feeds back to the system via **EtherNet/IP or PROFINET** for automatic width control, replacing manual measurements.

### 2. Neck-In & Edge Bead Monitoring

In cast film and extrusion coating, the sensors monitor the "neck-in" (the narrowing of the web) to control the final sheet width. The sensor could identify the transition from the thick edge bead to the flat film, guiding slitters to trim only the necessary amount.

### 3. Ridge & Structural Feature Detection

The sensors can detect structural features like ridges on extruded plastics (e.g., resealable zippers) or other profile anomalies, ensuring consistent product geometry.

### 4. Medical & Shrink Tube Extrusion

Single sensors are used for precise width measurement of narrow blown films used for shrink tubes or medical IV bags, where dimensional accuracy is critical for downstream performance.

## Supported Web Guiding Solutions

Maximize extruder yield with advanced guiding modes tailored for plastic film production.

- Web Oscillation: Critical for blown film. [Roll-2-Roll® Controllers](https://r2r.tech/products/controllers) can control the oscillation of the haul-off or winder to randomize gauge variations, ensuring flat, high-quality rolls.
- Center Guiding: Maintains the bubble or cast film centerline relative to the machine axis, ensuring even winding and downstream processing.
- Edge Guiding: Used for edge trimming to minimize waste by keeping the web positioned strictly for the slitters.

## Technical Comparison

**The "Scanner vs. Laser Pointer" Analogy:** Comparing an [Roll-2-Roll® Sensor](https://r2r.tech/products/sensors) to a standard fork style sensor is like comparing a flatbed scanner to a laser pointer. While a laser pointer sensor might lose a wandering web, the [Roll-2-Roll® Sensor](https://r2r.tech/products/sensors) (scanner) sees the entire oscillation path, maintaining a lock on the web edge regardless of lateral movement or neck-in variations.

- Oscillation Tracking: Competitors use motorized "Chaser" slides (mechanical wear). Roll-2-Roll Technologies uses Wide Sensor Array (Solid state, no moving parts).
- Measurement: Manual tape measure is unsafe. [Roll-2-Roll® Sensors](https://r2r.tech/products/sensors) offers Automated Real-Time Feedback.
- Edge Bead: Low-res sensors miss the transition. [Roll-2-Roll® Sensor](https://r2r.tech/products/sensors)'s 0.0635 mm Resolution saves resin.
- Simplicity: Vision systems are complex. [Roll-2-Roll® Sensor](https://r2r.tech/products/sensors) is Plug-and-Play.

---

# Flexible Printed Electronics

URL: https://r2r.tech/industries/flexible-printed-electronics.md

## Overview



Printing circuits (RFID, OLED, Solar) on flexible substrates combines the throughput of roll-to-roll manufacturing with the precision of semiconductor fabrication. R2R provides a **Vision System in a Sensor Package**, delivering the micron-level accuracy required for multi-layer registration without the complexity of traditional camera systems. Our **sub-pixel approximation** technology enables resolution down to 0.016 mm, ensuring perfect alignment of conductive traces and dielectric layers.




## The Engineering Challenge



Electronic functionality depends on perfect physical alignment in challenging environments.



- Registration Accuracy: Printing multiple conductive layers requires micron-level overlay accuracy. A slight misalignment breaks the circuit or reduces device performance.
- Vacuum Environments: Many processes (like sputtering or deposition) happen in a vacuum where pneumatic and ultrasonic sensors fail due to lack of air or sound propagation.
- Delicate Substrates: Materials like PET or PEN are thin and easily scratched, requiring non-contact sensing.




## The R2R Technical Advantage



We bring lab-quality measurement to the production floor with **operational simplicity**.



- 0.016 mm Resolution: Our sub-pixel approximation technology provides the extreme resolution necessary to align conductive traces and dielectric layers, far exceeding standard photo-eyes.
- Vacuum Compatibility: Fiber optics inherently work in vacuums. The passive sensor head contains no electronics that would outgas or overheat, making it ideal for deposition chambers.
- Fiducial Tracking: High-speed tracking of printed marks ensures layer-to-layer registration is maintained dynamically.
- Linear Optical Technology: Unlike traditional cameras with circular lenses that cause distortion, our patented fiber optic array provides 1:1 image magnification. This ensures measurement accuracy is not affected by the sensor's field of view.
- No Programming Needed: Unlike complex vision systems that require an expert to maintain, R2R systems are designed to be parameterized and operated by standard line operators.




## Key Applications




### 1. Multilayer Registration



Track fiducial marks to align print layers with sub-pixel accuracy. R2R sensors ensure that conductive inks, insulators, and active layers stack perfectly to create functional devices.




### 2. Flat Ribbon Cable Slitting



Used for slitting and quality control of flat ribbon cables. The sensor ensures precise width measurement of the insulated cables, verifying that conductors are properly spaced and the insulation width is within tolerance.




### 3. Printed Line Guiding



The system can guide the web based on a printed line or conductive trace rather than the physical edge of the web. This is critical for printed electronic circuits where the functional component must be aligned regardless of web edge variations.




### 4. Vacuum Deposition Guiding



Guide webs inside vacuum chambers for solar or OLED production. Our fiber-optic pass-throughs allow the electronics to stay outside the vacuum while the sensing happens inside.




### 5. Conductive Trace Inspection



Detect "opens" (breaks) in printed lines. Using the high-resolution camera capabilities, the sensor can verify the continuity of printed traces in real-time, flagging defects immediately.




## Supported Web Guiding Solutions



Micron-level control for functional electronics.



- Line & Contrast Guiding: The primary mode for printed electronics. Tracks fiducial marks or printed conductive lines to ensure layer-to-layer registration accuracy.
- Master-Slave Guiding: Essential for multi-layer lamination (e.g., encapsulation). The cover sheet (slave) follows the exact position of the active substrate (master) to prevent exposure.
- Center Guiding: Keeps delicate substrates (PET/PEN) centered in vacuum chambers or coating zones to prevent edge damage and ensure uniform deposition.




## Technical Comparison



**The "Scanner vs. Laser Pointer" Analogy:** Comparing an R2R Sensor to a standard photo-eye is like comparing a flatbed scanner to a laser pointer. A laser pointer is too crude to see a microscopic fiducial mark. The R2R Sensor (scanner) sees the entire "picture" of the web's edge and features, identifying the exact position of tiny registration marks with sub-pixel precision to align layers perfectly, all while remaining as easy to use as a standard office appliance.



- Precision: Standard sensors are ±0.1mm. R2R delivers 0.016 mm (16 microns).
- Environment: Electronics fail in vacuum. R2R's Passive Fiber Optics are vacuum-safe.
- Registration: Basic edge guiding isn't enough. R2R tracks Fiducials & Features.
- Simplicity: Vision systems need coding. R2R needs No Programming.

---

# Label & Narrow Web

URL: https://r2r.tech/industries/label-narrow-web.md

## Overview



The Narrow Web market is focused on label printing (flexo/digital) and converting. Space is the defining constraint. R2R delivers high-performance guiding that fits where others can't, offering a **lower initial cost** by integrating light source, optics, and camera into a single package. This **compact, one-sided solution** solves the industry's toughest material challenges like clear-on-clear detection with **no calibration required**.




## The Engineering Challenge



Label converters face physical and material constraints that limit productivity.



- Extreme Space Constraints: There is often no room for standard web guides. Controllers must be mounted remotely, and large sensor frames obstruct the operator's view and hand access.
- Matrix Removal Issues: Guiding the fragile waste skeleton after die-cutting is difficult; breaks stop the press.
- Clear-on-Clear Labels: Detecting a clear label on a clear liner to trigger a dispenser or check for missing labels is a known industry "Holy Grail" challenge.




## The R2R Technical Advantage



We engineered our solutions to disappear into the machine while providing superior visibility.



- Compact and One-Sided: Our sensors act as line scan cameras but fit in tight spaces (typically around 10-15 mm) due to their linear optical technology. The controller is located outside the guard door, saving valuable space inside the press.
- Integrated Architecture: The all-in-one sensor design removes the need for bulky gantries, allowing installation in tight gaps between print stations without separate light sources or frame grabbers.
- Refractive Detection: Utilizing the high dynamic range of our ODC sensors, we can detect the refractive difference of clear labels on clear liners without expensive capacitive sensors.
- Material-Independent: Works on paper, clear film, and metallic labels without recalibration.




## Key Applications




### 1. Low Profile Web Guiding



Install guides in tight spaces without compromising accessibility. Our compact actuators and remote electronics allow for seamless integration into crowded label presses.




### 2. Die-Cut Feature Tracking



The sensor can detect the edge of a die-cut label relative to the release liner, measuring the gap or "matrix" width. This ensures the waste matrix is stable and prevents breaks that stop the press.




### 3. Clear-on-Clear Detection



Solve the "missing label" problem. Because the sensors can see "through" materials to some extent or use contrast, they are effective at detecting clear labels on clear liners, ensuring 100% product quality verification where traditional sensors struggle.




### 4. Release Liner Slitting



Ensures the precise width of the release liner in label stock production. The sensor acts as a high-speed line camera to monitor slit widths, ensuring all lanes are present and within tolerance.




## Supported Web Guiding Solutions



Compact and precise solutions for the narrow web market.



- Edge Guiding: The workhorse of the label industry. Keeps the web aligned into the printing press or die station. R2R's low-profile guides fit where others can't.
- Line & Contrast Guiding: Guides the web based on a printed line or a contrast edge (like the edge of a label matrix) rather than the physical material edge. Critical for multi-pass printing or die-cutting registration.
- Rewind Guiding: Ensures finished label rolls are wound perfectly straight ("flat disk" winding) for high-speed application lines.




## Technical Comparison



**The "Scanner vs. Laser Pointer" Analogy:** Comparing an R2R Sensor to a standard photo-eye is like comparing a flatbed scanner to a laser pointer. A standard photo-eye (laser pointer) shines *through* a clear label and sees nothing. The R2R sensor (scanner) sees the *refraction* of light at the label's edge, creating a clear picture of where the label starts and stops, even on a clear liner.



- Space Claim: Competitors use bulky frames. R2R offers Low Profile / Remote Electronics.
- Clear Labels: Capacitive sensors are expensive/finicky. R2R uses Optical Refraction (Standard Sensor).
- Installation: Retrofitting is difficult with C-frames. R2R's One-Sided Mount simplifies upgrades.
- Flexibility: Standard sensors do one thing. R2R sensors are Multifunctional.

---

# Metal Processing

URL: https://r2r.tech/industries/metal-processing.md

## Overview



Coil coating, steel, and aluminum processing involve heavy, rigid webs in harsh environments defined by oil, vibration, and impact. R2R delivers robust sensing capable of managing the extreme physical characteristics of metal strips. With **environmental robustness** and a **Vision System in a Sensor Package** design, our sensors reduce maintenance and downtime while fitting where bulky C-frames cannot.




## The Engineering Challenge



Metal processing combines heavy mechanical forces with difficult optical properties.



- Camber: Metal strips often have a "banana" curve. This creates immense lateral forces. Measuring this camber in real-time is crucial for steering the uncoiler.
- Reflection (Glare): Polished metals reflect light like a mirror (specular reflection), blinding standard optical sensors that rely on diffuse reflection.
- Physical Durability: Sensors must withstand accidental impact from heavy strips and operate in oily environments.




## The R2R Technical Advantage



We combine rugged hardware with smart optical filtering and **installation advantages**.



- Reflective Surface Handling: R2R's Spatial Filtering technology manages specular reflection effectively. It ignores the glare and locks onto the scattering from the edge, ensuring stable guiding on polished aluminum or steel.
- Abrasive Environment Ready: Because the sensor uses 1:1 optical magnification and advanced algorithms, it can be mounted further away from the web (up to 3 inches in some cases) to avoid damage from abrasive metal strips or web flutter.
- Wide Sensor Range: With sensor widths up to 960 mm, the system can measure strip curvature (camber) continuously without mechanical tracking or motorized positioners.
- One-Sided Mounting: In vertical accumulators or annealing lines where two-sided frames are impossible to mount, the R2R one-sided sensor mounts easily to the machine frame.




## Key Applications




### 1. Camber Detection



Using wide-range sensors to measure the strip curvature (camber) continuously. This data drives the uncoiler to pivot and compensate, preventing telescoping rolls and side-wall damage.




### 2. Vacuum Coating Operations



Roll-2-Roll® sensors are robust enough to operate inside vacuum chambers, making them ideal for metal coating or metallizing processes where standard sensors fail. Ideally suited for accumulator & annealing lines.




### 3. Strip Width Measurement



Used for measuring the width of metal strips during converting or manufacturing. The **Linear Optical Technology** provides distortion-free imaging for accurate validation of the final product width.




## Supported Web Guiding Solutions



Heavy-duty control for high-tension metal processing.



- Center Guiding: The preferred method for coil processing. Two sensors track the strip edges to keep the coil centered entering the furnace or coating head, regardless of width variations.
- Unwind & Rewind Guiding: Hydraulically or electromechanically shifts the heavy uncoiler/recoiler to ensure the strip feeds straight and winds perfectly, preventing telescoped coils.
- Edge Guiding: Used for edge trimming operations where the strip must be positioned precisely relative to the knives to minimize scrap.




## Technical Comparison



**The "Scanner vs. Laser Pointer" Analogy:** Comparing an R2R Sensor to a standard photo-eye is like comparing a flatbed scanner to a laser pointer. Glare from polished metal blinds a standard photo-eye (laser pointer) like a mirror reflecting into your eye. The R2R sensor (scanner) uses spatial filtering to "see through" the glare, focusing only on the scattered light from the physical edge of the strip.



- Glare: Blinds standard optics. R2R uses Spatial Filtering to ignore specular reflection.
- Mounting: Requires heavy C-frames. R2R uses One-Sided Beam Mounting.
- Camber: Difficult to track with narrow sensors. R2R's Wide Sensor tracks full movement.
- Durability: Standard sensors are fragile. R2R is built for Harsh Environments.

---

# Nonwovens & Hygiene

URL: https://r2r.tech/industries/nonwovens-hygiene.md

## Overview



The nonwovens sector (diapers, sanitary napkins, medical textiles) processes materials that are lightweight, highly porous, and fragile. R2R sensors excel here because with **One Sensor for Any Material**—capable of detecting porous webs that baffle traditional ultrasonic or air sensors without requiring any calibration. We offer a **Vision System in a Sensor Package** that requires **no programming** and sets up in minutes.




## The Engineering Challenge



Standard sensors often fail due to the unique physical properties of nonwoven webs.



- Porosity & Signal Loss: Nonwovens are nets of fibers. Sound passes through them (confusing ultrasonic sensors), and air passes through them (useless for pneumatic sensors). Optical sensors often "see through" the gaps, causing the web guide to oscillate wildly.
- Material Fragility: Low-basis weight webs are easily stretched or distorted. Contact sensors are impossible to use.
- Dust & Contamination: The environment is filled with cellulose fibers and Superabsorbent Polymer (SAP) dust that coats lenses, blinding standard photo-eyes.




## The R2R Technical Advantage



Our technology uses a fiber-optic array that "sees" the web structure, functioning as a **one-dimensional line scan camera**.



- Fiber Detection, Not Gap Detection: Because we rely on light scattering, we detect the fibers themselves. This provides a stable signal on even the most porous, low-basis weight nonwovens where others fail.
- No Calibration Required: The system does not require calibration when switching materials; it can accurately detect the edge of a porous mesh or a clear film immediately without setup changes.
- Dust Immunity: The fiber-optic design and infrared spectrum make the system robust against dust accumulation. The sensor can often "see" through a layer of dust that would blind a standard camera.
- Wide Viewing Area: Accommodates the significant neck-in and width variations common in varying tension zones of nonwoven lines (up to 960mm).




## Key Applications




### 1. Porous Material Handling



Unlike air or ultrasonic sensors that struggle with porous materials, these sensors accurately detect the edge of high-porosity nonwovens and meshes without calibration. This ensures stable guiding on breathable films, spunbond, and meltblown materials.




### 2. Diaper Manufacturing



Used to measure the width of folded layers to prevent cosmetic defects and functional failures (e.g., glue buildup caused by incorrect folding). In multi-layer lamination, the **Material-Independent** sensor handles opaque backsheets and porous topsheets with a single setting.




### 3. Glue Application Monitoring



Using UV light sources, the sensors can track the width and position of UV fluorescent glue lines on hygiene products, ensuring proper adhesive application and reducing product failure.




### 4. SAP Dust Environments



Reduce cleaning downtime. R2R sensors maintain operation in high-dust zones where cellulose and polymer particulates accumulate, keeping high-speed hygiene lines running longer between maintenance stops.




## Supported Web Guiding Solutions



Versatile guiding for hygiene product assembly.



- Center Guiding: Critical for diaper and pad lines where multiple layers of varying widths must be centered relative to each other.
- Master-Slave Guiding: Synchronizes the position of a specialized layer (e.g., acquisition layer) to the position of the main chassis web, ensuring perfect construction alignment.
- Edge Guiding: Reliable guiding of the main nonwoven web into the converting process, using our fiber-optic sensors to ignore porosity.




## Technical Comparison



**The "Scanner vs. Laser Pointer" Analogy:** Comparing an R2R Sensor to a standard photo-eye is like comparing a flatbed scanner to a laser pointer. A laser pointer sensor sees a hole in a nonwoven web and thinks the web is gone. An R2R sensor (scanner) sees the pattern of fibers and understands "this is a porous web," maintaining stable guiding without false corrections, all while remaining **Simple to Operate**.



- Porous Materials: Ultrasonic sensors see "holes." R2R sees Fibers (Stable signal).
- Contamination: Standard lenses get blocked by dust. R2R's Fiber Optic Design offers superior dust immunity.
- Setup: Requires tuning for opacity/density. R2R requires No Calibration for density changes.
- Cost: Vision systems need experts. R2R needs No Programming.

---

# Paper & Printing

URL: https://r2r.tech/industries/paper-printing.md

## Overview



High-speed printing and paper converting are driven by speed, often reaching 2000 fpm. R2R sensors provide stable guiding that ignores the flutter and dust inherent to high-speed paper processing. By integrating **line scan camera technology** into a sensor package, we offer the precision of vision systems without the high cost or engineering complexity. Our **linear optical technology** ensures distortion-free imaging even at top speeds.




## The Engineering Challenge



Speed creates instability that confuses standard sensors.



- Web Flutter: At high speeds, paper webs flutter aerodynamically. This vertical movement causes standard sensors to misread the lateral position (parallax error).
- Dust: Paper dust is abrasive and coats lenses, reducing signal strength over time.
- Splice Damage: Undetected splices can damage delicate printing plates or blankets, causing expensive downtime.




## The R2R Technical Advantage



Our optical design is inherently stable against Z-axis movement and tough environments.



- Flutter Immunity: The collimated light source and spatial filtering of the R2R sensor make it insensitive to plane changes (flutter). It tracks the true edge position regardless of vertical web movement.
- Dust Robustness: The infrared light source and fiber-optic design penetrate dust buildup better than visible light sensors, reducing cleaning frequency.
- No Calibration Required: The system does not require calibration when switching paper grades; it can accurately detect the edge immediately without setup changes.
- Spatial Awareness: Unlike analog edge sensors, these sensors can detect multiple edges, thread counts, or specific features within their view.




## Key Applications




### 1. Slitting Quality Control



Used to measure paper width during slitting operations to ensure tolerance adherence. The sensor's depth of field ensures that vertical web movement (flutter) is not misinterpreted as lateral shift, preventing "ghost" corrections and maintaining precise register.




### 2. Coating Width & Presence



Detects the presence and width of coatings on paper (e.g., adhesives or chemical treatments) by analyzing the contrast difference between the coated and uncoated sections. This ensures uniform application and reduces material waste.




### 3. Splice & Tear Detection



The sensor possesses **spatial awareness** to detect the sudden density change of a splice or the absence of material (tear) at full line speed, triggering safety gates or rejection systems to protect print heads.




### 4. Corrugated Board Measurement



Dual sensor setups are used to measure the total width of wide corrugated boards, ensuring the final product meets dimensional specifications.




## Supported Web Guiding Solutions



High-speed precision for printing and paper converting.



- Line & Contrast Guiding: The standard for printing. Guides the web based on a printed line or pattern to ensure colors overlap correctly (registration) or die-cuts match the print.
- Edge Guiding: Maintains the paper web position into the printing press or slitter.
- Center Guiding: Used when paper roll widths vary or when the web must be centered for coating/laminating operations.
- Unwind & Rewind Guiding: Ensures stable web entry and perfectly wound final rolls, critical for preventing edge damage during transport.




## Technical Comparison



**The "Scanner vs. Laser Pointer" Analogy:** Comparing an R2R Sensor to a standard photo-eye is like comparing a flatbed scanner to a laser pointer. A laser pointer's dot jumps around on a fluttering web, causing false readings. An R2R sensor (scanner) sees the entire "picture" of the edge position relative to the sensor regardless of whether the paper moves up or down (flutter), ensuring stability where simple sensors fail.



- Flutter: Causes parallax error in standard sensors. R2R's Collimated Optics are immune.
- Dust: Coats lenses quickly. R2R's Infrared Source penetrates dust better.
- Speed: Standard sensors lag. R2R enables Real-Time Correction at 2000 fpm.
- Cost: Vision systems are expensive. R2R offers Camera Performance at Sensor Cost.

---

# Pharma & Medical

URL: https://r2r.tech/industries/pharma-medical.md

## Overview



Medical packaging and transdermal patches require 100% defect-free production. Regulatory compliance (FDA 21 CFR Part 11) drives a need for data validation. R2R provides a **Vision System in a Sensor Package** that offers the clean, traceable, and precise web handling solutions demanded by the pharmaceutical industry. With **comprehensive inspection capabilities** and **no programming needed**, our systems offer validated precision without the complexity of custom vision systems.




## The Engineering Challenge



Medical converting combines strict quality standards with difficult materials.



- Validation & Traceability: Manufacturers must prove that every millimeter of the web was aligned and inspected.
- Contamination Risks: Equipment must be cleanable. Mechanical moving parts (like motorized sensor slides) generate particulates and are a contamination risk.
- Complex Materials: Tyvek (porous), clear forming films, and foil backings are often used on the same line, requiring a sensor that handles all without recalibration.




## The R2R Technical Advantage



Our solutions are built for clean rooms and data-driven manufacturing with **operational simplicity**.



- Clean Room Compliance: The one-sided, fully enclosed sensor design minimizes particle traps and is easy to wipe down. The lack of moving parts makes it ideal for sterile environments.
- 0.016 mm Precision: Sub-pixel resolution ensures absolute alignment for critical registration tasks, functioning as a high-precision vision system.
- Data Connectivity: Our SCU6x controller offers Industrial Ethernet (EtherNet/IP, PROFINET), allowing position data to be logged to the PLC for batch validation. App-based logging can also export CSVs for QA records.
- Material-Independent: Handles Tyvek, foil, and film interchangeably without setup changes. No calibration required when switching materials reduces changeover risks.




## Key Applications




### 1. Medical Packaging Inspection



Used in slitter rewinders for pharmaceutical packaging materials where 100% inline inspection is required. The system validates that slit widths meet strict QC lab standards without stopping the machine for manual sampling, ensuring regulatory compliance.




### 2. Blister Pack Registration



Ensure the foil backing aligns perfectly with the formed plastic blister. R2R sensors track printed registration marks or the physical edge of the blister formation with 0.016 mm precision to prevent seal breaches.




### 3. IV Bag Manufacturing



Accurate width measurement for narrow blown film used in IV bags. The sensor ensures the dimensional integrity of the tubing, which is critical for medical dosing and fluid delivery.




### 4. Void Detection



The sensor's simple inspection capability detects voids (e.g., missing tablets in a blister stream) before sealing, preventing defective product from leaving the line.




### 5. Clean Room Guiding



Eliminate contamination sources. Our solid-state sensing and electromechanical guiding replace hydraulic systems and open mechanical slides, maintaining ISO clean room standards.




## Supported Web Guiding Solutions



Validated precision for medical manufacturing.



- Center Guiding: Ensures that forming films and backing foils are perfectly centered during the blistering process.
- Line & Contrast Guiding: Tracks printed registration marks on lid foil to ensure that text and branding align perfectly with the sealed blister packs.
- Edge Guiding: Used for general web transport of medical grade papers, Tyvek, and films through coating or sterilization processes.




## Technical Comparison



**The "Scanner vs. Laser Pointer" Analogy:** Comparing an R2R Sensor to a standard photo-eye is like comparing a flatbed scanner to a laser pointer. A laser pointer sensor might miss a tiny void or misread a Tyvek edge due to texture. The R2R sensor (scanner) verifies the integrity of the seal area and the presence of the product with complete **spatial awareness**, ensuring patient safety.



- Cleanliness: Competitors use Motorized Slides (Particulates). R2R uses Solid State Sensing (Clean).
- Validation: Standard systems are "Black Boxes." R2R offers Full Ethernet Data Logging.
- Tyvek Handling: Porosity confuses ultrasonics. R2R handles Tyvek, Foil, & Film equally well.
- Simplicity: No complex setup. R2R is Plug-and-Play.

---

# Textile & Composites

URL: https://r2r.tech/industries/textile-composites.md

## Overview



Carbon fiber manufacturing and textile production require sensing systems that can see "Black-on-Black" and handle complex textures. R2R brings **Vision System Capabilities** to the production floor in a rugged, easy-to-use package. Our sensors utilize **spatial awareness** to detect thread counts, gaps, and edges on low-contrast materials without the need for expensive engineering or calibration.




## The Engineering Challenge



Detecting dark materials against dark backgrounds is a persistent problem in composites.



- Carbon Fiber "Black-on-Black": Detecting the edge of black carbon fiber against a black roller or conveyor belt is incredibly difficult for standard optical sensors due to lack of contrast.
- Tow Spreading & Gaps: Individual carbon fiber tows must be spread to form a seamless sheet. Unnoticed gaps reduce structural integrity.
- High Temperature: Oxidation ovens operate at high heat, destroying standard electronics inside the process zone.




## The R2R Technical Advantage



Our technology sees texture where others see only color, with **versatility** for challenging materials.



- Contrast Detection: The sensor's ability to discriminate based on light scattering texture rather than just color allows it to see "Black on Black"—detecting carbon fiber edges against dark backgrounds where others fail.
- Wide Viewing Area: Allows tracking of wide sheets or multiple tows with a single sensor unit (up to 960mm), eliminating the need to reposition sensors for different widths or use expensive motorized positioners.
- Line Scan Camera Technology: High-resolution pixel arrays enable counting of individual threads and precise gap measurement.
- Environmental Robustness: Fiber optic cables allow the electronics to be mounted away from the high heat of oxidation ovens or abrasive environments.
- Modularity: A sensor used for web guiding can be repurposed for thread counting or flag detection, protecting your investment.




## Key Applications




### 1. Thread and String Counting



The sensor functions as a vision system to count individual threads or strings (e.g., for tire cord or elastic waistbands) and measure the gaps between them. This ensures density consistency and detects broken threads immediately.




### 2. Selvage Measurement



Measures the width of the selvage (the self-finished edge of fabric) to minimize trim waste. Accurate monitoring allows for tighter control of the textile finishing process.




### 3. Carpet Manufacturing



Tracks the tufting edge to measure the effective width of the carpet. The **Wide Viewing Area** allows tracking of wide materials without needing to reposition sensors.




### 4. Process Monitoring



Measures width changes caused by expansion and contraction during dyeing and heating processes. The sensor provides real-time feedback on material dimensional stability under thermal stress.




### 5. Tow Width & Gap Measurement



A bank of R2R sensors monitors the width of individual tows and detects gaps between them during the spreading process, ensuring uniform sheet formation.




## Supported Web Guiding Solutions



Robust guiding for flexible and textured materials.



- Center Guiding: Crucial for carpet and wide-textile manufacturing. Ensures the heavy, often variable-width web remains centered for coating or tufting.
- Edge Guiding: Standard guiding for selvedge alignment in weaving or finishing lines. R2R sensors handle the "fuzzy" edge of textiles better than air sensors.
- Unwind Guiding: Controls the payout of fabric rolls into the process, preventing wrinkles and tension issues from the start.




## Technical Comparison



**The "Scanner vs. Laser Pointer" Analogy:** Comparing an R2R Sensor to a standard photo-eye is like comparing a flatbed scanner to a laser pointer. On a black carbon fiber web, a laser pointer sees nothing—just darkness. The R2R sensor (scanner) sees the weave pattern (texture) of the fiber versus the smooth belt, allowing it to "see" the edge even when there is no color contrast, all while being **Plug-and-Play**.



- Contrast: Standard sensors fail on Black-on-Black. R2R uses Texture/Scattering Detection.
- Tow Monitoring: Requires multiple narrow sensors. R2R uses Wide Array Sensors (fewer units).
- Resolution: Analog sensors can't see threads. R2R offers Line Scan Precision.
- Heat: Electronics fail in ovens. R2R's Fiber Optics withstand high temperatures.

---

# Tire & Rubber

URL: https://r2r.tech/industries/tire-rubber.md

## Overview

Building tires involves layering sticky rubber, steel belts, and fabric cords. The defining challenge is contrast: detecting black material on black backgrounds. [Roll-2-Roll® Sensors](https://r2r.tech/products/sensors) are a **Vision System in a Sensor Package** that relies on **spatial awareness** and texture differentiation rather than color contrast. This allows for robust guiding of tire components where standard photo-eyes fail, with **no calibration required** for material changes.

## The Engineering Challenge

Rubber processing presents unique optical and mechanical difficulties.

- Contrast (Black on Black): Detecting the edge of black rubber on a black conveyor belt is extremely difficult for standard optical sensors due to the lack of light reflection difference.
- Width Variation: Rubber is elastic; its width changes with tension. Monitoring this variation is vital for tire balance and uniformity.
- Adhesion: Materials are sticky, making contact sensors impossible to use.

## The R2R Technical Advantage

We don't rely on color contrast; we rely on surface texture and **linear optical technology**.

- Contrast Sensitivity via Spatial Awareness: The sensor detects the texture difference between the rubber (matte/textured) and the belt (smooth/worn), enabling reliable guiding even with zero color contrast.
- Wide Dynamic Range: The sensor can handle the varying reflectivity of rubber compounds without saturation or signal loss.
- Wide Sensor Range: With sensor widths up to 960 mm, the system can accommodate various tire component widths without the need to mechanically move the sensor, eliminating expensive positioners.
- No Programming Needed: Simple "teach" functions allow operators to reset guide points instantly through the controller interface without writing code.

## Key Applications

### 1. Black-on-Black Measurement

Measuring black rubber against a black background is challenging. These sensors can be installed over a white roller (or with a white background reference) to create a contrast difference, allowing for accurate width measurement of tire plies and treads where other sensors fail.

### 2. Calendering Uniformity

Monitors the width of the rubber sheet as it is flattened during the calendering process to ensure uniformity. Precise alignment here prevents internal tire defects and structural weaknesses.

### 3. Tire Building

Ensures the cut rubber sheets have the correct dimensions before they are wrapped around the tire-building drum. This step is crucial for maintaining the balance and safety of the final tire.

### 4. Inner Liner Width Measurement

Measure the width of the inner liner sheet before cutting. R2R sensors provide continuous feedback on width consistency, ensuring the liner meets tire specifications.

## Supported Web Guiding Solutions

High-contrast control for tire components.

- Center Guiding: Used for aligning tire cord and tread layers. Maintains the symmetry of the tire construction, which is vital for balance and performance.
- Edge Guiding: Guides rubber strips and inner liners into cutters or winders. Our texture-based sensing handles black rubber on black belts where others fail.
- Master-Slave Guiding: Synchronizes the position of multiple ply layers during assembly to ensure they are stacked directly on top of one another.

## Technical Comparison

**The "Scanner vs. Laser Pointer" Analogy:** Comparing an R2R Sensor to a standard photo-eye is like comparing a flatbed scanner to a laser pointer. A laser pointer sees black rubber and a black belt as identical—darkness. An R2R sensor (scanner) sees the entire "picture" of the web's texture (the grain of the rubber vs. the weave of the belt), allowing it to find the edge where others see nothing, all while remaining as easy to use as a standard office appliance.

- Contrast: Fails with Black-on-Black. R2R uses Texture Discrimination.
- Material: Sticky rubber fouls contact sensors. R2R is 100% Non-Contact.
- Width: Difficult to measure elastics. R2R provides Real-Time Width Data.
- Simplicity: No complex vision setup. R2R is Plug-and-Play.

---

# 1.5in Mounting Bracket for WPS and ODC Sensors

URL: https://r2r.tech/documentation/3d-models/15in-mounting-bracket-wps-and-odc-sensors.md

### 1.5" Mounting Bracket for WPS and ODC

---

# 1DC 192

URL: https://r2r.tech/documentation/3d-models/1dc-192.md

1DC 192

---

# 1DC 192 xx-QD

URL: https://r2r.tech/documentation/2d-drawings/1dc-192-xx-qd.md

1DC 192 xx-QD

---

# 1DC 288-xx

URL: https://r2r.tech/documentation/3d-models/1dc-288-xx.md

1DC 288-xx

---

# 1DC 288-xx QD

URL: https://r2r.tech/documentation/2d-drawings/1dc-288-xx-qd.md

1DC 288-xx QD

---

# 1DC 384

URL: https://r2r.tech/documentation/3d-models/1dc-384.md

1DC 384

---

# 1DC 384-xx QD

URL: https://r2r.tech/documentation/2d-drawings/1dc-384-xx-qd.md

1DC 384-xx QD

---

# 1DC 480

URL: https://r2r.tech/documentation/3d-models/1dc-480.md

1DC 480

---

# 1DC 480-xx QD

URL: https://r2r.tech/documentation/2d-drawings/1dc-480-xx-qd.md

1DC 480-xx QD

---

# 1DC 768

URL: https://r2r.tech/documentation/3d-models/1dc-768.md

1DC 768

---

# 1DC 768-xx QD

URL: https://r2r.tech/documentation/2d-drawings/1dc-768-xx-qd.md

1DC 768-xx QD

---

# 1DC 96

URL: https://r2r.tech/documentation/3d-models/1dc-96.md

1DC 96

---

# 1DC 96-xx QD

URL: https://r2r.tech/documentation/2d-drawings/1dc-96-xx-qd.md

1DC 96-xx QD

---

# 1DC 960

URL: https://r2r.tech/documentation/3d-models/1dc-960.md

1DC 960

---

# 1DC 960-xx QD

URL: https://r2r.tech/documentation/2d-drawings/1dc-960-xx-qd.md

1DC 960-xx QD

---

# 1DC Product Brochure

URL: https://r2r.tech/documentation/brochures/1dc-product-brochure.md

1DC Product Brochure

---

# 1DC Series: Product Data Sheet

URL: https://r2r.tech/documentation/manuals/1dc-series-product-data-sheet.md

1DC Series: Product Data Sheet

---

# 1in Mounting Bracket for WPS and ODC Sensors

URL: https://r2r.tech/documentation/3d-models/1in-mounting-bracket-wps-and-odc-sensors.md

### 1" Mounting for WPS and ODC Sensors

---

# 24 V DC Input Power Cable 2D Drawing

URL: https://r2r.tech/documentation/2d-drawings/24-v-dc-input-power-cable-2d-drawing.md

24 V DC Input Power Cable 2D Drawing

---

# 28in Web Guide Assembly -- Low Profile Web Guide

URL: https://r2r.tech/documentation/3d-models/28in-web-guide-assembly-low-profile-web-guide.md

28in Web Guide Assembly -- Low Profile Web Guide

---

# 761KS12 Sealed Power Plug, 0.10" (2.5mm) center pin

URL: https://r2r.tech/documentation/2d-drawings/761ks12-sealed-power-plug-010-25mm-center-pin.md

761KS12 Sealed Power Plug, 0.10" (2.5mm) center pin, tip insulator color black, Cable OD range 0.125"-0.150" [3.2-3.8mm]

---

# Application Survey Paper Copy

URL: https://r2r.tech/documentation/product-sheets/application-survey-paper-copy.md

Application Survey Paper Copy

---

# ARIS Compact Web Guiding System Product Manual (V2)

URL: https://r2r.tech/documentation/manuals/aris-compact-web-guiding-system-product-manual-v2.md

The ARIS web guiding system brings an innovative way of guiding the web to the converting industry; a guiding system that does not require any setup or manual recalibration after product changeovers. The technology in ARIS can adjust automatically to the physical characteristics of the web material, correctly positioning the material through the process.

---

# ARIS Compact Web Guiding System Product Manual (V2.2)

URL: https://r2r.tech/documentation/manuals/aris-compact-web-guiding-system-product-manual-v22.md

This product manual provides information about installation, use and maintenance of ARIS Web Guiding System (WGS). The web guiding system is designed for use in indoor industrial and laboratory equipment that process materials in web form as they move through a converting or raw material manufacturing process.

---

# ARIS Retrofit Kit Product and User Manual

URL: https://r2r.tech/documentation/manuals/aris-retrofit-kit-product-and-user-manual.md

The retrofit kit for upgrading any web guide mechanism.

---

# ARIS SCU5 EtherNet/IP Configuration Manual

URL: https://r2r.tech/documentation/manuals/aris-scu5-ethernetip-configuration-manual.md

ARIS SCU5 EtherNet/IP Configuration Manual

---

# ARIS Web Position Sensor Product Manual

URL: https://r2r.tech/documentation/manuals/aris-web-position-sensor-product-manual.md

ARIS Web Position Sensor Product Manual

---

# ARIS WPS 440 Product Manual (Generic Version)

URL: https://r2r.tech/documentation/manuals/aris-wps-440-product-manual-generic-version.md

This is the generic version of the product manual for ARIS WPS 440. Please note that the sensor has multiple applications and the product manual would be specific for the end customer application. 

---

# BLA-015-0600-TG or BLA-030-0600-TG

URL: https://r2r.tech/documentation/3d-models/bla-015-0600-tg-or-bla-030-0600-tg.md

BLA-015-0600-TG or BLA-030-0600-TG Upgrade Actuator

---

# BLA-067-0600-TG

URL: https://r2r.tech/documentation/2d-drawings/bla-067-0600-tg.md

BLA-067-0600-TG

---

# BLA-0xx-0600-TG 2D Drawing

URL: https://r2r.tech/documentation/2d-drawings/bla-0xx-0600-tg-2d-drawing.md

BLA-0xx-0600-TG 2D Drawing
Ball Screw Linear Actuator

---

# CA761KS07984 2 Meter Molded Sealed DC Power Cable Assembly, 0.10" (2.5mm) center pin, tip insulator color black

URL: https://r2r.tech/documentation/2d-drawings/ca761ks07984-2-meter-molded-sealed-dc-power-cable-assembly-010-25mm.md

CA761KS07984 2 Meter Molded Sealed DC Power Cable Assembly, 0.10" (2.5mm) center pin, tip insulator color black

---

# CARA761KS07984 2 Meter Molded Sealed DC Power Cable Assembly, 0.10" (2.5mm) center pin, tip insulator color black, Right Angle

URL: https://r2r.tech/documentation/2d-drawings/cara761ks07984-2-meter-molded-sealed-dc-power-cable-assembly-010-25mm.md

CARA761KS07984 2 Meter Molded Sealed DC Power Cable Assembly, 0.10" (2.5mm) center pin, tip insulator color black, Right Angle

---

# Case Study - Line Guiding Application

URL: https://r2r.tech/documentation/case-studies/case-study-line-guiding-application.md

## Application



Tracking a printed line within other lines using Roll-2-Roll® Sensor System.



## Customer



Converter of Precision Die-Cut Components in Indiana



Engineering Manager Customer



## Problem/Challenge



Our customer needed three web guides urgently for a line guiding application. The solutions they had found were very expensive and did not provide a solution to their problem. They had been manually guiding an expensive specialty material, with a high cost of downtime and wasted materials.. The material had to be guided based on a line that was within other lines. We were contacted by them and during the conversation we understood that there were three main issues: guide a web on a line within other lines, compact design of the web guide, and lead time.



## Our Solution



We offered a compact web guide system with contrast sensing for line guiding, with integrated operator interface display and 10 inch rollers for plug and play installation and operation. After installing the first two units, the customer approached us again with an interesting request: they wanted to be able to use the web guide in both directions. Web guiding dynamics does not allow for a web guiding system to guide in both directions. We came up with a simple solution: Install the web guide on a plate that would rotate horizontally 180o to reverse the direction of guiding. This required the addition of a remote operator interface to allow access to the operator upon turning the web guide direction.



![Contrast Sensing Applications](https://r2r.tech/sites/default/files/inline-images/Untitled%20presentation%20%283%29_3.jpg)



##



## Results or Customer Satisfaction



At the end, the customer was very happy with the technology and the support provided. Their ROI improved significantly due to an extreme reduction in wasted material and downtime. [Read more their testimonial.](https://r2r.tech/testimonials/solving-difficult-line-guiding-problem-no-one-else-could)



## Benefits



- Quality of production - Greater reliability than other suppliers options
- Downtime reduction - Elimination of manual guidance
- Operation cost reduction - downtime reduction through elimination of manual guidance, savings from reduction of wasted material, high cost materials
- Investment Savings - Less expensive than other alternatives



## Why the customer chose us



**Nobody could offer them a solution of guiding on a line that was within other lines**, and the options offered were expensive and did not solve the problem

---

# Case Study - Pneumo-hydraulic North American Web Guide Upgrade

URL: https://r2r.tech/documentation/case-studies/case-study-pneumo-hydraulic-north-american-web-guide-upgrade.md

## Application



North American web guide upgrade pneumo-hydraulic web guide.



## Customer



Company: **North Atlantic Specialty Bag - Pennsylvania**



Project Lead: : **Pat Trenkle - President**



## Customer Problem/Challenge



We were referred to the customer by another customer. They currently had a North American web guide on a 16” Mark Andy press. The web guide was not working, their print quality was suffering, and they could not find spare parts to get their web guide in good working condition. We contacted the customer and arranged a visit with our regional sales representative to discuss the option of a Web Guide Upgrade application. Pat Trenkle of North Atlantic explained the issues that they were facing in their production line. They had issues with tension control and the web guiding system. Luckily, the mechanical components on their web guide were in good condition or could be maintained with readily accessible components of the shelf.



## Our Solution



Our solution was to upgrade their old North American web guide with the Roll-2-Roll® Web Guide upgrade kit of a controller, sensor and actuator. This setup would allow North Atlantic Specialty Bag to keep the mechanical components of their web guide and upgrade the control and sensor to the latest and most advanced web guiding technology in the industry. This upgrade was performed in our facility with a quick turnaround time of one week. They bolted the web guide, sensor and controller to their machine and their converting line was back in operation with better quality than before.



![SCU5 Controller](https://r2r.tech/sites/default/files/inline-images/Controler_burlapWeb%20%283%29_0.jpg)



## Results or Customer Satisfaction



The customer was satisfied with us working to fix their problem without having to change their process or product. They liked the innovative approach to the problem and the non-traditional solution given. **[Read more about their satisfaction in this testimonial](https://r2r.tech/testimonials/north-american-web-guide-upgrade)**.



## Benefits



- Downtime avoidance - Elimination of possible complete failure of existing web guides
- Technical Support - Custom counts on the immediate attention of the service team.
- Investment Savings - Alternative to costly replacement of complete units.
- Product Quality - Improved print quality



## Why the customer chose us?



Simplicity in upgrade process and previous experience of another customer who recommended us to the new customer.

---

# CASE STUDY - Pneumo-Hydraulic Web Guide Upgrade

URL: https://r2r.tech/documentation/case-studies/case-study-pneumo-hydraulic-web-guide-upgrade.md

## Application



Pneumo-Hydraulic Web Guide Upgrade 



## Customer



Company: **Dallas Plastics - Wentzville, MO**



Project Lead: **Dennis Sampson - Plant Superintendent**



## Customer Problem/Challenge



The customer runs several blown film lines. Each line comes equipped with at least one pneumo-hydraulic off-set pivot guide on each of their lines. Most of these systems are old and the manufacturers of several of these web guides were no longer in existence, or had discontinued the manufacture of the models in use. They have no replacement parts or service. They were facing losses from unnecessary downtime and product scrap. Hydraulic leaks were causing issues of safety and loss of materials from contamination. The solution they had received so far from their current web guide suppliers was to replace complete web guiding systems on all converting lines within the next couple of years. This was a very expensive solution. Then a GWD pneumo-hydraulic web guide stopped working during the night shift and they needed a fast solution.



## Our Solution



We presented the alternative of upgrade kits that would replace certain components of the web guide and would use the same mechanical components. The upgrade would require a controller, sensor, actuator, motor driver and all peripheral connectors. After discussions on specific details for connecting the actuator to the web guide frame, shipping of the parts was achieved in less than one week. Our technical personnel guided their maintenance team through the entire process until they had a running converting line again. Understanding the urgency of the problem they were facing, we issued a price quote for the upgrade kit that same day. Typically, the lead time is 4 weeks, but for this project we were able to ship within a week of receiving the PO.



![Pneumo-hydraulic Upgrade Kit](https://r2r.tech/sites/default/files/inline-images/Retrofit%20Kit2_7.jpg)



## Results or Customer Satisfaction



Our technical staff was in contact with their maintenance personnel constantly to guide them through the installation process and first runs. We trained their staff, both English and Spanish speaking, to make sure they understood the controller operation. They were happy to have found a less expensive option than complete replacement of the web guides, fast lead lead time and commissioning of the web guide, and simple system to operate with user friendly operator interface. **[Read the customer's testimonial.](https://r2r.tech/testimonials/plant-superintendent-uses-web-guide-upgrade-kits-their-converting-lines)**



## Benefits



- Downtime avoidance
- Operation cost reduction
- Investment Savings
- Safety - Elimination of slip hazard
- Product Quality - Removal of hydraulic units eliminated product contamination from hydraulic leaks



## Why the customer chose us?



An affordable option to replacing entire web guide systems. Easier to operate and maintenance free guide system. Fast lead times. Excellent product support.



##  

---

# Case Study - Uneven Edge Guiding - Specialty Sensing

URL: https://r2r.tech/documentation/case-studies/case-study-uneven-edge-guiding-specialty-sensing.md

## Application



Uneven Edge Guiding using Line Guiding of Web - Sensor Upgrade with the latest Roll-2-Roll® Sensor System.



## Customer



Company: **OEM of Web Handling Equipment for the Converting Industry - Illinois**



Project Lead: **Lead Project Controls Engineer - Engineering**



## Customer Problem/Challenge



The customer required a web guiding solution for a web with a saw tooth edge. Our competitors could only follow the edge with their sensor and controller, so the web guide would move according to the contour of the web. The customer wanted a system that would guide the web in a straight fashion. After testing the web guiding and sensing solutions of another major manufacturer, they proved that they needed a new technology that could solve their problem.



![Uneven edges](https://r2r.tech/sites/default/files/inline-images/square-edges_0.png)



## Our Solution



The Lead Project Controls Engineer had been informed by a colleague that he knew of us as he had worked previously with us at the Web Handling Research Center at Oklahoma State University. We offered them a SCU5 D controller and WPS 48 white light sensor to connect to their current web guiding system. The sensor and controller could be connected to their current guiding system. They would have the capability of edge and line guiding. The system would guide on a printed feature on the web.



![Specialty Guiding Application - Uneven Edges](https://r2r.tech/sites/default/files/inline-images/square-edges-solution_0.png)



## Results or Customer Satisfaction



The customer was satisfied with us working to fix their problem without having to change their process or product. They liked the innovative approach to the problem and the non-traditional solution given. **[Read more about their satisfaction in this testimonial.](https://r2r.tech/testimonials/specialty-sensing-application-converters-uneven-edge-guiding)**



## Benefits



- Quality of production - Better edge detection
- Downtime reduction - Avoidance of production stoppage due to web guide failure and elimination of calibration of sensor on changing web material
- Investment Savings - Upgrade allowed for use of existing web guide mechanism



## Why the customer chose us?



The competition was not able to provide them a solution as they did not quite understand the customer’s problem.

---

# Case Study - Web Guide Upgrade with Roll-2-Roll Web Guide Upgrade Kit

URL: https://r2r.tech/documentation/case-studies/case-study-web-guide-upgrade-roll-2-roll-web-guide-upgrade-kit.md

## Application



Web Guide Upgrade Edge Guiding



## Customer



Company: Plastic Film Manufacturer in North East US



Project Lead: Steven Fiedorczyk - Maintenance Manager



## Customer Problem/Challenge



Our customer had several converting lines with web guides running on old and outdated electronics. They were facing complete failure or existing web guides, no spares or support from their current supplier, and complex operation and upkeep. Replacing with new units from the same supplier would still have the issues of complexity and cost of purchasing new web guide systems. web guides it seemed that their only solution was to buy complete web guide systems. The most urgent application required a solution that would allow for center guiding of webs with widths ranging from 40 inches to 80 inches..



## Our Solution



Our sales representative for that region visited their facility and introduced our customer to our technology. The customer knew our sales rep well and had worked with him for many years in the converting industry. After some conversations the customer decided to look at the web guide upgrade kit as an alternative to their problem. After reviewing the characteristics of the actuator (stroke, mountings and thrust), we were able to provide an upgrade system that included two sensors each with a 17 inch range, a controller, a motor driver and an actuator with the appropriate connections to facilitate installation in the existing web guide mechanism. The solution provided a center guiding option that would not require physical repositioning of sensors when faced with width changes and edge detection that did not require calibration of the sensors under changing material or environmental conditions.



![Web Guide Upgrade Kit](https://r2r.tech/sites/default/files/inline-images/Retrofit%20Kit2%20%281%29_1.jpg)



## Results or Customer Satisfaction



The first system proved to the customer that this would be a great solution for the rest of their aging web guide systems. They proceeded to purchase additional units to cover a range of web guiding applications with single edge guiding or center guiding on lines processing different web widths. **[Read the customer's testimonial.](https://r2r.tech/testimonials/web-guide-upgrade-kit-application-several-converting-lines)**



## Benefits



- Cost Savings - Avoided a costly replacement of web guides, less expensive than other alternatives
- Downtime Avoidance - Eliminations of possible complete failure of existing web guides
- Operation Cost Reduction - downtime reduction by eliminating reposition of sensors for width changes



## Why the customer chose us?



The customer was impressed with the elimination of sensor repositioning. We offered a solution that required less investment and guaranteed operation of the equipment for an extended time.

---

# Case Study - Wide Web Guide System for Textiles

URL: https://r2r.tech/documentation/case-studies/case-study-wide-web-guide-system-textiles.md

## Application



Wide Web Guide System for Textile Converting.



## Customer



Company: **Hanesbrands - North Carolina**



Project Lead: **Richard Horton - Engineering Automation Department**



## Customer Problem/Challenge



Our customer had to feed fabric through a series of feed conveyor belts and the fabric had to be exactly centered on the belts because a special polymer material had to be applied to the fabric as it fed through the feed belts and had to always be applied exactly down the center of the fabric. They had looked at multiple Vision systems and sensors that could possibly be used to verify that the fabric was always fed straight and centered. If not, they would have to stop the process and correct the fabric. Their concern with vision systems was the upkeep and training of personnel, specially in operations outside of the US. They also looked at possibly building some type of unit to assist with keeping the fabric centered.



## Our Solution



We provided them with a complete wide web guide mechanism for center guiding to test. We helped them in the installation, start-up and operation of the web guide.



Results or Customer Satisfaction After the initial test the customer decided to purchase the unit and informed us that they would purchase more units as these would be used in a few of their plants. The one purchased was going to be shipped out of the country. The customer was impressed at how simple it was to install and operate. They were very happy in not having to go with a vision system or having to design a guiding system. **[You can read more on the customer’s experience in their testimonial.](https://r2r.tech/testimonials/wide-web-guide-system-textile-fabric)**



![Wide Web Guides](https://r2r.tech/products/web-guides/wide-web-guides)(https://r2r.tech/sites/default/files/inline-images/GuidingSystemedit_1.jpg)



## Benefits



- Reduced Downtime - Did not have to worry to stop the line to correct the position of the web
- Cost of Project - No investment in costly vision system or in inhouse development and manufacture of guiding solution
- Simple to Install and Operate - They were confident that they could send the equipment to facilities out of the US to have the plant personnel install and operate the web guide.



## Why the customer chose us?



We offered a simple, easy to install and operate web guiding system. They considered training personnel on the system would not be difficult.

---

# Case Study Contrast Sensing Web Guiding for Textiles Converting

URL: https://r2r.tech/documentation/case-studies/case-study-contrast-sensing-web-guiding-textiles-converting.md

## Application



Upgrade of a web guide system for specialty center guiding with the latest Roll-2-Roll® Sensor System for Contrast Sensing.



## Customer



Specialty Textiles Manufacturer - Illinois



James Iglesias - Maintenance Engineer



## Customer Problem/Challenge



Our customer wanted to guide the web based on a center selvage. They could not find a reasonable solution and had developed an in-house system that did not provide a satisfactory result. Our solution involved a contrast sensing application.



![Center Selvage in a Textile Web](https://r2r.tech/sites/default/files/inline-images/Center%20Selvage%20Guiding_0.jpg)



## Our Solution



We offered them a SCU5 controller and WPS 221 white light sensor to connect to their current web guiding system. This would provide a detection of the position of the selvage within the specified tolerances and would give the output to the web guide mechanism to correctly position the web by using the contrast sensing application.



![Contrast Sensing Applications](https://r2r.tech/sites/default/files/inline-images/Untitled%20presentation%20%283%29_2.jpg)



## Results



Once the personnel became familiar with the system they were satisfied with the results of the selvage guiding application. The customer liked the plug and play capacity of the systems and the uniqueness of the technology, considering that they had not found a reasonable application to solve their problem. The customer was able to avoid purchasing expensive replacement solutions that would have to be engineered to their specifications. [Read more in their testimonial.](https://r2r.tech/testimonials/selvage-guiding-textiles-contrast-sensing)



## Benefits



- Quality of production - Material was kept in line based on the position of the selvage
- Downtime reduction - Increased reliability of the system, less time spent working on adjusting the web guiding system.
- Investment Savings - Upgrade allowed for use of existing web guide mechanism



## Why the customer chose us



We provided **a simple to install and operate solution** for a problem that no one else has been able to help with.

---

# CASE STUDY: Compact Web Guide with Ethernet Communication

URL: https://r2r.tech/documentation/case-studies/case-study-compact-web-guide-ethernet-communication.md

## Application



Compact Web Guide Ethernet Communication for Web Guiding Replacement



## Customer



Company: Manufacturer of Window Coverings, Colorado



Project Lead: Automation and Controls Engineer - New Product Development



## Customer Problem/Challenge



The customer wanted to replace an old web guide system. The solution required integration, ease of use and lead time. His application was for a narrow web fabric at less than 50 fpm with a variety of colors and textures. This application required edge guiding.



## Our Solution



The customer came across our website while searching online and reviewing the current manufacturer and other competitors web guides. He found the information and technology we provided interesting and contacted us after watching the webinar on advanced web guiding Typically, we recommend an upgrade of the current web guide, where the controller, sensor and actuator are replaced with Roll-2-Roll Technologies equipment. The customer preferred a complete solution. The system included a 15" web guide mechanism, a controller with Ethernet I/P communications and a WPS 48 Infrared sensor for edge guiding. Delivery was made in accordance with the lead time agreed upon with the customer. Support was always available during the installation and start-up process.



![Compact Web Guiding Systems](https://r2r.tech/sites/default/files/inline-images/CompacWebGuidingSystemfromRoll2RollTechnologies%20%282%29_2.jpg)



## Results or Customer Satisfaction



At the end the customer was very satisfied with the product and support. A few months later they purchased an additional web guide with similar characteristics. **[You can read the customer’s testimonial.](https://r2r.tech/testimonials/replacing-old-web-guides-compact-solution-ethernet-communication)**



## Benefits



Downtime avoidance - Elimination of possible complete failure of existing web guides



Operation cost reduction - downtime reduction through elimination of repositioning of sensors in width changes



Investment Savings - Less expensive than other alternatives Integration to their control system



## Why the customer chose us?



We offered a compact web guide system that included Ethernet communications and a sensor technology that allowed them to operate without downtime to adjust sensors for the conditions of their converting process. Our short lead time was better than competitors had offered them.

---

# CASE STUDY: Pneumo-hydraulic Web Guide Upgrade of a GWD Web Guide MA 2200

URL: https://r2r.tech/documentation/case-studies/case-study-pneumo-hydraulic-web-guide-upgrade-gwd-web-guide-ma-2200.md

## Application



Pneumo-Hydraulic Web Guide Upgrade of out dated web guide system



## Customer



Company: **LabelTeq Unlimited, Inc**



Project Lead: **Paul Black**



## Customer Problem/Challenge



**The customer had an old General Web Dynamics web guide installed on their Mark Andy 2200 7" press.** This particular model uses a hydraulic actuator. The existing web guide started to throw the web to the side causing breaks in the web. This created unnecessary downtime to fix the broken web, reset the web guide, and thread the web through the press. Additionally, they were facing increasing scrap from the damaged web. The operators of the line were becoming frustrated by the recurring issue with the web guide. As the problem progressed it was found that the hydraulic pump that powered the cylinder used as the actuator was failing. At the end, they decided to run without the web guide, risking problems in their final product. It was not a condition that they were willing to maintain too long as the web was not guaranteed to be aligned in the press. Most of the solutions available involved replacing the complete web guide with a brand new one. None of the web guide manufacturers contacted offered a retrofit or upgrade kit of the web guide because it was no longer manufactured and the original manufacturer no longer existed. Cost and ease of installation was still an issue in selecting this. They looked for different solutions and felt that it would be better to change the hydraulic actuator to an electromechanical system.



## Our Solution



We offered an upgrade kit with an electromechanical actuator, controller, and sensor that would provide them with the latest in web guiding technology in the industry. Our proposed solution included a drop-in electromechanical actuator and our services to upgrade the web guide in our facility, along with the controller, motor driver and sensor.



![Web Guide Upgrade Kit](https://r2r.tech/sites/default/files/inline-images/Retrofit%20Kit2%20%281%29_0.jpg)



## Results or Customer Satisfaction



At the end, the customer was happy to solve their issue with the failing web guide. The operators were very happy to have a sound web guiding solution. After this experience, the customer is sure that they are qualified to do a future upgrade in much less time than this first experience and are very satisfied with the performance of the upgrade. Read the testimonial



## Benefits



- Downtime reduction
- Reduction of material waste
- Ease of operation
- Maintenance expense reduction



## Why the customer chose us?



We were the only manufacturer that could upgrade their aging web guide system. It was a solution that allowed them a technologically and operationally more advanced and efficient system at a fraction of the cost offered by competitors.

---

# CASE STUDY: Web Guide Sensor Upgrade - Metal Lamination

URL: https://r2r.tech/documentation/case-studies/case-study-web-guide-sensor-upgrade-metal-lamination.md

## Application



Web Guide Sensor Upgrade for Existing Web Guide, Lamination on Metals



## Customer



Company:** American Nickeloid Company**



Project Lead: **Henry Maze - Plant Engineer Customer**



## Problem/Challenge



A premier supplier of continuous coated metal coil products had a failing sensor and controller on a web guide mounted on a laminating converting line. This was starting to affect their production efficiency through increasing downtime. At some point the system would completely fail and possibly cause a complete shutdown of the production line. The line of web guides had been discontinued. There was no technical support or spare parts for the system. The sensor and controller had started to fail, and the option offered by web guide manufacturers was to purchase a complete system. Additionally, their lines ran multiple materials for laminating the metal sheet, so they would have to calibrate sensors to adjust to changing materials and environmental conditions.



## Our Solution



The customer started an online search for alternative solutions and found one of our YouTube videos. They like the capability to “see” clear, porous, and non-porous webs without the need to calibrate the sensor. Additionally, they liked the upgrade kits for web guiding as they would be able to use the existing web guide mechanism by replacing the sensor and control. After several email exchanges the customer selected a WPS 48 IR sensor with an SCU5 D controller for sensor applications. The controller was later upgraded to an SCU5 C(E)D with EtherNet Communications for integration with their converting line controls. Even though their line processed different web widths, it was set up to have one edge at the same location in the converting line. This allowed for the use of the smaller sensor.




 ![](https://lh6.googleusercontent.com/bS4EGdwS33TkOYWo_Xr-reKlPog6TSzXLgh_JG2L__0HpVdsIdtIcvAD8CGa13xp4g9J_Rk_wUT7y93SGgYjiXY2uuH2sJ210weCW3Xhr6g-Q5enQRAD-vx8zL3kXJtekf2Jd1xT=s0)



## Results or Customer Satisfaction



The customer avoided an impending line shutdown from a complete sensor and controller failure. They were happy with the support as we worked through their problem. They found the sensor technology very practical and advanced in comparison with fork style sensors and other options. They look forward to approaching us for future applications. **[Read their testimonial.](https://r2r.tech/testimonials/edge-guiding-sensor-upgrade-application)**



## Benefits



- Quality of production - Better edge detection
- Downtime reduction - Avoidance of production stoppage due to web guide failure and elimination of calibration of sensor on changing web material
- Investment Savings - Upgrade allowed for use of existing web guide mechanism



## Why the customer chose us?



Best option for edge sensing dealing with different materials. Ability to integrate to other manufacturer’s web guide as an upgrade. Excellent technical support.

---

# CASE STUDY: Web Guide Upgrade Kit for Aging Web Guides

URL: https://r2r.tech/documentation/case-studies/case-study-web-guide-upgrade-kit-aging-web-guides.md

## Application



Web Guide Upgrade



## Customer



Company: **Cenveo - Massachusetts**



Project Lead: **Jason Hinkle - General Manager Customer**



## Problem/Challenge



A major printer in the New England region had several web guiding systems with failing controllers, sensors and actuators. The mechanical components of the web guide were in good condition and did not need replacing. The web guides were from different manufacturers and their only solution seemed to be replacing all web guides with new units, as none offered parts or support to refurbish the web guides.



## Our Solution



We were approached by their engineering department and we offered them the option of using upgrade kits with drop in actuators. This would allow them to keep the web guide mechanism and they would upgrade their sensor, controller and actuator to the latest technology in the industry. They purchased one kit and we did the installation in our facility with a turnaround of three weeks.



![Web Guide Upgrade Kit](https://r2r.tech/sites/default/files/inline-images/Retrofit%20Kit2%20%281%29_2.jpg)



## Results or Customer Satisfaction



The initial trial was successful and they upgraded several web guide units. All the units were upgraded at our facility with a turnaround time of about three weeks as requested by the customer. The customer felt that we provided incredible service and amazing products. [Read their testimonial.](https://r2r.tech/testimonials/incredible-service-amazing-products-web-guide-upgrade-applications)



## Benefits



- Investment Savings - much less expensive solution than replacing web guides with complete new units.
- Improved Performance and Quality - from the advanced sensor and control technology



## Why the customer chose us?



**We provided a solution that other web guide manufacturers could not, upgrade the existing web guides**. This gave them a significant cost savings and improved performance from the advanced technology their guides now had. The customer was happy with the support given during the analysis phase of the issue they were having with their web guides.

---

# CASE STUDY: Web Guide Upgrade of Pneumo-hydraulic Web Guide for a Slitting Operation

URL: https://r2r.tech/documentation/case-studies/case-study-web-guide-upgrade-pneumo-hydraulic-web-guide-slitting.md

## Application



Web Guide Upgrade of Pneumo-hydraulic Web Guide with no Spare Parts or Support



## Customer



Company: **Neeltran**



Project Lead: **Marc Vidal Customer**



## Problem/Challenge



A converter in Connecticut was running a slitter line without its web guide system. The pneumo-hydraulic web guide was out of service, and the manufacturer no longer provided support or spare parts. They had to manually position the roll several times a day to keep the web inline. The process was time consuming and they were facing increasing downtime and man hours to reposition the web. They had a final breakdown that would not allow them to reposition the web manually and they were faced with the purchase of a new web guide system.



## Our Solution



They found us through an internet search. We offered them an upgrade kit that would eliminate the pneumo-hydraulic components of their web guide. It was less expensive than acquiring a new web guide, and could be sourced within a few weeks. Additionally, they would have a web guide system with the latest in sensor and control technology.



![Web Guide Upgrade Kit](https://r2r.tech/sites/default/files/inline-images/Retrofit%20Kit2%20%281%29_3.jpg)



## Results or Customer Satisfaction



The customer was able to put their line back in operation within a few weeks and the need for manual repositioning of the web was eliminated completely. The advanced technology allowed it to run faster and continuously. The customer was very impressed with the performance and was willing to recommend the upgrade kit option to other converters as an option to replace complete web guide systems. **[Read their Testimonial](https://r2r.tech/testimonials/upgrade-our-web-aligner-works-great-we-are-highly-thrilled)**



## Benefits



- Downtime elimination
- Improved Process Quality
- Savings in Investment
- Elimination of Pneumo-hydraulic Cost



## Why the customer chose us?



The web guide upgrade kit allowed them to recover their web guide system and eliminate the cost of running a less precise pneumo-hydraulic web guide system. They believed that the advanced technology in controls and sensors would allow them to be more efficient and they confirmed it after installing the first system.

---

# Compact Web Guiding System Product Brochure

URL: https://r2r.tech/documentation/brochures/compact-web-guiding-system-product-brochure.md

The product brochure is a summary of the features and benefits of the compact web guiding system.

---

# Compact Web Guiding System Product Manual (V2.4)

URL: https://r2r.tech/documentation/manuals/compact-web-guiding-system-product-manual-v24.md

This product manual provides information about installation, use and maintenance of Compact Web Guiding System. The web guiding system is designed for use in indoor industrial and laboratory equipment that process materials in web form as they move through a converting or raw material manufacturing process.

---

# Contrast guiding performance of web guides

URL: https://r2r.tech/documentation/white-papers/contrast-guiding-performance-web-guides.md

## Introduction



In most roll-to-roll applications, the web is guided based on the edge position of the material. Often this alignment based on web edge is sufficient. However, in certain applications the alignment may be based on a feature on the web that is not the edge. In some converting applications the web is guided based on a continuous printed line or a continuous contrasting feature on the material. Line guiding and contrast guiding applications are common in converting processes related to printing, coating, slitting and lamination.



When the guiding is not based on the edge, traditional edge sensors (infrared, ultrasonic or pneumatic) cannot provide the desired web position measurement based on a line or a contrasting feature on the web. In these scenarios, expensive camera based sensors are employed. However, the Roll-2-Roll® Sensor technology provides a simple and cost effective solution for contrast guiding applications. A [previous white paper demonstrated the contrast sensing capability of the Web Position Sensor](http://r2r.tech/documentation/sensor-line-guiding-and-contrast-guiding-applications). This white paper discusses the contrast and line guiding performance with the Roll-2-Roll Technologies web position sensor technology.



## Contrast Guiding Performance



The contrast guiding performance is evaluated with a compact web guiding system equipped with the ARIS WPS 16 WL sensor. The detailed specification of the parameters of the compact web guide used in these experiments are shown in the table below.



## Experimental roll-to-roll machine



An in-house closed-loop roll-to-roll experimental platform (see Fig. 1) is used to evaluate the contrast guiding performance. The length of web material threaded in the machine is about 20 meters and the web can be transported at a speed of up to 10 meters/sec. The web tension in the machine is maintained using a pneumatic dancer system. Webs with 100 mm and up to 450 mm in width can be transported in the machine. The machine is also equipped with two web guides to regulate web position. Two spans with a total length of 1200 mm separate the two web guides. For experimental purposes the upstream guide is used to create disturbances while the downstream guide is used to correct for the disturbances.

 ![The Experimental roll-to-roll machine used for testing the web guides.](https://r2r.tech/sites/default/files/inline-images/Test-Machine_2.png)

A composite web with die cut labels on a clear release liner was transported in the roll-to-roll experimental platform for the experiments. The web was guided based on the die cut edge of the label instead of clear release liner edge. An ARIS WPS 16 WL sensor provided the contrast position feedback to the compact web guiding system.



Two additional sensors, with a sensing window of 16 mm (see Fig. 2), were used to measure the contrast position before and after the downstream web guide. These sensors provide a clear quantification of the magnitude of lateral disturbance entering the web guide and the corrective response of the web guide.

 ![Configuration of sensors used to measure the disturbance entering the web guide and leaving the web guide. The upstream sensor (left) is located at a span before the web guide and the downstream sensor (right) is located one span downstream of the web guide.The data from the two sensors are recorded at 50 Hz and also displayed on the LCD screen (left).](https://r2r.tech/sites/default/files/inline-images/contrast-sensors-upstream-and-downstream-of-web-guide.png)

## Sinusoidal Disturbance Rejection Performance



Contrast guiding performance is quantified based on observing the disturbance rejection capabilities of the web guide. Sinusoidal lateral disturbances with a magnitude of 8 mm and frequencies of 0.25 Hz, 0.5 Hz and 1 Hz were introduced with the upstream web guide. The downstream web guide was used to correct the disturbances. The magnitude of the distance entering the web guide and the magnitude of the same disturbance after the correction by the web guide were measured using two additional sensors.



Fig. 3, Fig. 4 and Fig. 5 show a representative sample of results. The web speed in the experiments was 1.94 m/sec and the disturbance frequencies were 0.25 Hz, 0.5 Hz and 1 Hz.

 ![Contrast guiding performance with a sinusoidal disturbance with a frequency of 0.25 Hz. Web speed 1.94 m/sec. Dashed red line shows the disturbance magnitude entering the web guide while the blue line shows the disturbance rejection performance of the web guide. ](https://r2r.tech/sites/default/files/inline-images/Sinusoidal-disturbance-025Hz-web-speed-350fpm.png)![Contrast guiding performance with a sinusoidal disturbance with a frequency of 0.5 Hz. Web speed 1.94 m/sec. Dashed red line shows the disturbance magnitude entering the web guide while the blue line shows the disturbance rejection performance of the web guide. ](https://r2r.tech/sites/default/files/inline-images/Sinusoidal-disturbance-05Hz-web-speed-350fpm.png)![Contrast guiding performance with a sinusoidal disturbance with a frequency of 1 Hz. Web speed 1.94 m/sec. Dashed red line shows the disturbance magnitude entering the web guide while the blue line shows the disturbance rejection performance of the web guide.](https://r2r.tech/sites/default/files/inline-images/Sinusoidal-disturbance-1Hz-web-speed-350fpm.png)

Magnitude of disturbance attenuation at all frequencies were signification as seen from the plots above. The time domain data is further summarized in Fig. 6, which shows the FFT of the contrast position measurement before and after the compact web guiding system. A similar summary for a slower speed of 0.97 m/sec is shown in Fig. 7.

 ![A summary of the contrast guiding performance of the web guide in the frequency domain. The web transport speed at different frequencies was 1.94 m/sec or 350 feet-per-minute. The FFT of the sensor measurement upstream and downstream of the web guide is shown to quantify the contrast guiding performance. As seen from the plot the upstream disturbances are significantly reduced by the compact web guiding system. ](https://r2r.tech/sites/default/files/inline-images/FFT-sinusoidal-disturbance-summary-speed-350fpm.png)![A summary of the contrast guiding performance of the web guide in the frequency domain. The web transport speed at different frequencies was 0.97 m/sec or 175 feet-per-minute. The FFT of the sensor measurement upstream and downstream of the web guide is shown to quantify the contrast guiding performance. As seen from the plot the upstream disturbances are significantly reduced by the compact web guiding system.](https://r2r.tech/sites/default/files/inline-images/FFT-sinusoidal-disturbance-summary-speed-175fpm.png)

## Conclusion



The experimental results show that the contrast guiding performance of the compact web guiding system is similar to the edge guiding performance seen in the previous white paper. The similar performance is attributed to the precision, accuracy and linearity of the ARIS sensor technology for contrast sensing applications. Since the sensor is unaffected by the material properties the performances are similar.

---

# Dimensional drawing of Compact Web Guiding System

URL: https://r2r.tech/documentation/2d-drawings/dimensional-drawing-compact-web-guiding-system.md

Dimensional drawing of the Compact Web Guiding System

---

# Dimensional drawing of Low Profile Web Guide - U Pattern

URL: https://r2r.tech/documentation/2d-drawings/dimensional-drawing-low-profile-web-guide-u-pattern.md

Dimensional drawing of Low Profile Web Guide - U Pattern

---

# Dimensional drawing of Low Profile Web Guide - Z Pattern

URL: https://r2r.tech/documentation/2d-drawings/dimensional-drawing-low-profile-web-guide-z-pattern.md

Dimensional drawing of Low Profile Web Guide - Z Pattern

---

# Dimensional drawing of Wide Web Guides

URL: https://r2r.tech/documentation/2d-drawings/dimensional-drawing-wide-web-guides.md

Dimensional drawing of the Wide Web Guides

---

# EtherCAT ECS File for SCU5 firmware Version 3.5+ using Hilscher Module

URL: https://r2r.tech/documentation/support-files/ethercat-ecs-file-scu5-firmware-version-35-using-hilscher-module.md

EtherCAT ECS File for SCU5 firmware Version 3.5+ using Hilscher Module

---

# EtherNet/IP EDS File for Roll-2-Roll® Communication Module

URL: https://r2r.tech/documentation/support-files/ethernetip-eds-file-roll-2-rollr-communication-module.md

EtherNet/IP EDS File for Roll-2-Roll® Communication Module

---

# EtherNet/IP EDS File for SCU5 firmware Version 3.5+ using Hilscher Module

URL: https://r2r.tech/documentation/support-files/ethernetip-eds-file-scu5-firmware-version-35-using-hilscher-module.md

EtherNet/IP EDS File for SCU5 firmware Version 3.5+ using Hilscher Module

---

# EtherNet/IP EDS File for SCU5 firmware Version 3.5+ using HMS Module

URL: https://r2r.tech/documentation/support-files/ethernetip-eds-file-scu5-firmware-version-35-using-hms-module.md

EtherNet/IP EDS File for SCU5 firmware Version 3.5+ using HMS Module

---

# EtherNet/IP EDS File for SCU6x firmware Version 4.1+ using Hilscher Module

URL: https://r2r.tech/documentation/support-files/ethernetip-eds-file-scu6x-firmware-version-41-using-hilscher-module.md

EtherNet/IP EDS File for SCU6x firmware Version 4.1+ using Hilscher Module

---

# General Product Brochure - 4 Page

URL: https://r2r.tech/documentation/brochures/general-product-brochure-4-page.md

Summary of all the product groups available for the converting industry. The product brochure includes summaries of web position sensors, controller, web guiding systems, and data analytics package. Highly accurate sensors that are adaptive, smartest controllers that are easy to operate, easy to use intelligent web guiding systems, powerful data analytics processing to bring clarity to the web handling process

---

# Installation of Displacement Guide

URL: https://r2r.tech/documentation/manuals/installation-displacement-guide.md

Displacement guide or the offset-pivot guide is an ideal web guide that can be used within any intermediate location of the machine. When properly installed this web guide introduces the least amount of stresses in the web due to its corrective action. With the two guide rollers moving in tandem the correction happens in the exit span.



Read the attached document for more information.

---

# Installation of Steering Guide

URL: https://r2r.tech/documentation/manuals/installation-steering-guide.md

Steering guide use should be limited to some special case where a long entry span is available since the working principle involves bending of the web to correct the lateral position. Steering guides require additional design considerations to ensure that the web guide performs as expected without causing any damage to the web. Most of the correction of the steering guide happens in the entry span due the rotation and translation of the guide roller.



Read the attached document for more information.

---

# LHS-005-0125-LP: 2D Drawing (dxf)

URL: https://r2r.tech/documentation/2d-drawings/lhs-005-0125-lp-2d-drawing-dxf.md

LHS-005-0125-LP: 2D Drawing (dxf)

---

# LHS-005-0400-LP

URL: https://r2r.tech/documentation/3d-models/lhs-005-0400-lp.md

LHS-005-0400-LP: Small web guide actuator

---

# LHS-005-0400-LP: 2D Drawing (dxf)

URL: https://r2r.tech/documentation/2d-drawings/lhs-005-0400-lp-2d-drawing-dxf.md

LHS-005-0400-LP: 2D Drawing (dxf)

---

# LHS-005-0xxx-LP: 2D Drawing (pdf)

URL: https://r2r.tech/documentation/2d-drawings/lhs-005-0xxx-lp-2d-drawing-pdf.md

LHS-005-0xxx-LP: 2D Drawing (pdf)

---

# LHS-015-0150-WG: 2D Drawing (pdf)

URL: https://r2r.tech/documentation/2d-drawings/lhs-015-0150-wg-2d-drawing-pdf.md

LHS-015-0150-WG: 2D Drawing (pdf)

---

# LHS-020-0400-RF

URL: https://r2r.tech/documentation/3d-models/lhs-020-0400-rf.md

LHS-040-0600-RF -- Retrofit Actuator for Supported Rails

---

# LHS-020-0400-TG

URL: https://r2r.tech/documentation/3d-models/lhs-020-0400-tg.md

LHS-020-0400-TG -- Retrofit Actuator with Side Support

---

# LHS-020-0600-RF

URL: https://r2r.tech/documentation/3d-models/lhs-020-0600-rf.md

LHS-020-0600-RF -- Retrofit Actuator for Supported Rails

---

# LHS-020-0xxx-RF: 2D Drawing (dxf)

URL: https://r2r.tech/documentation/2d-drawings/lhs-020-0xxx-rf-2d-drawing-dxf.md

LHS-020-0xxx-RF: 2D Drawing (dxf)

---

# LHS-020-0xxx-RF: 2D Drawing (pdf)

URL: https://r2r.tech/documentation/2d-drawings/lhs-020-0xxx-rf-2d-drawing-pdf.md

LHS-020-0xxx-RF: 2D Drawing (pdf)

---

# LHS-020-x400-TG

URL: https://r2r.tech/documentation/2d-drawings/lhs-020-x400-tg.md

Retrofit actuator with front rod eye and rear eye.

---

# LHS-030-xxxx-RF

URL: https://r2r.tech/documentation/3d-models/lhs-030-xxxx-rf.md

LHS-030-xxxx-RF -- High thrust retrofit actuator without linear support

---

# LHS-030-xxxx-RF: 2D Drawing (pdf)

URL: https://r2r.tech/documentation/2d-drawings/lhs-030-xxxx-rf-2d-drawing-pdf.md

LHS-030-xxxx-RF: 2D Drawing (pdf)

---

# Low Profile Web Guide Product Manual (V2.4)

URL: https://r2r.tech/documentation/manuals/low-profile-web-guide-product-manual-v24.md

This product manual provides information about installation, use and maintenance of the Low Profile Web which is powered by the ARIS Web Position Sensors and the ARIS SCU5 controller. The web guiding system is designed for use in indoor industrial and laboratory equipment that process materials in web form as they move through a converting or raw material manufacturing process.

---

# Low Profile Web Guides Product Brochure

URL: https://r2r.tech/documentation/brochures/low-profile-web-guides-product-brochure.md

The product brochure is a summary of the features and benefits of the low profile web guides.

---

# M12 12-pin Female to Pigtail 10m (Murr 7000-19041-7051000)

URL: https://r2r.tech/documentation/product-sheets/m12-12-pin-female-pigtail-10m-murr-7000-19041-7051000.md

M12 12-pin Female to Pigtail 10m (Murr 7000-19041-7051000)

---

# M12 12-pin Female to Pigtail 10m (Turck RK 12T-10)

URL: https://r2r.tech/documentation/product-sheets/m12-12-pin-female-pigtail-10m-turck-rk-12t-10.md

M12 12-pin Female to Pigtail 10m (Turck RK 12T-10)

---

# M12 12-pin Female to Pigtail 3m (Murr 7000-19041-7050300)

URL: https://r2r.tech/documentation/product-sheets/m12-12-pin-female-pigtail-3m-murr-7000-19041-7050300.md

M12 12-pin Female to Pigtail 3m (Murr 7000-19041-7050300)

---

# M12 12-pin Female to Pigtail 3m (Turck RK 12T-3)

URL: https://r2r.tech/documentation/product-sheets/m12-12-pin-female-pigtail-3m-turck-rk-12t-3.md

M12 12-pin Female to Pigtail 3m (Turck RK 12T-3)

---

# M12 12-pin Female to Pigtail 5m (Murr 7000-19041-7050500)

URL: https://r2r.tech/documentation/product-sheets/m12-12-pin-female-pigtail-5m-murr-7000-19041-7050500.md

M12 12-pin Female to Pigtail 5m (Murr 7000-19041-7050500)

---

# M12 12-pin Female to Pigtail 5m (Turck RK 12T-5)

URL: https://r2r.tech/documentation/product-sheets/m12-12-pin-female-pigtail-5m-turck-rk-12t-5.md

M12 12-pin Female to Pigtail 5m (Turck RK 12T-5)

---

# M12 to RJ45S, Shielded Cable (Turck RSS RJ45S 441-xM)

URL: https://r2r.tech/documentation/product-sheets/m12-rj45s-shielded-cable-turck-rss-rj45s-441-xm.md

M12 to RJ45S, Shielded Cable (Turck RSS RJ45S 441-xM)

---

# M12 to RJ45S, Shielded Cable - 16.4ft/5m (Murr 7700-44711-S4U0500)

URL: https://r2r.tech/documentation/product-sheets/m12-rj45s-shielded-cable-164ft5m-murr-7700-44711-s4u0500.md

M12 to RJ45S, Shielded Cable - 16.4ft/5m (Murr 7700-44711-S4U0500)

---

# M12 to RJ45S, Shielded Cable - 16.4ft/5m (Phoenix Contact 1407362)

URL: https://r2r.tech/documentation/product-sheets/m12-rj45s-shielded-cable-164ft5m-phoenix-contact-1407362.md

M12 to RJ45S, Shielded Cable - 16.4ft/5m (Phoenix Contact 1407362)

---

# M12 to RJ45S, Shielded Cable - 32.8ft/10m (Murr 7700-44711-S4U1000)

URL: https://r2r.tech/documentation/product-sheets/m12-rj45s-shielded-cable-328ft10m-murr-7700-44711-s4u1000.md

M12 to RJ45S, Shielded Cable - 32.8ft/10m (Murr 7700-44711-S4U1000)

---

# M12 to RJ45S, Shielded Cable - 9.8ft/3m (Murr 7700-44711-S4U0300)

URL: https://r2r.tech/documentation/product-sheets/m12-rj45s-shielded-cable-98ft3m-murr-7700-44711-s4u0300.md

M12 to RJ45S, Shielded Cable - 9.8ft/3m

---

# Master/Slave Web Guiding System Installation

URL: https://r2r.tech/documentation/manuals/masterslave-web-guiding-system-installation.md

Master/slave guiding is a technique used to align two layers of web material, one on top of the other. This process involves measuring the position of the unguided master web, which serves as the base substrate. The position measurement is then relayed to a slave web guiding system. The slave web guide utilizes this information, known as the guidepoint offset, to accurately guide the web material. As the master web moves, the guide point of the slave web is adjusted accordingly, ensuring that the web is guided to a new location that maintains proper lamination between the two webs.

 

Read the attached document for more information:

---

# Material Agnostic Fiber Optic Web Edge Sensor

URL: https://r2r.tech/documentation/white-papers/material-agnostic-fiber-optic-web-edge-sensor.md

## Introduction



ARIS WPS is a revolutionary web edge sensor technology that employs fiber optics to accurately determine the position of a web material irrespective of its material properties. This edge sensing principle is unique and provides a true, absolute web position measurement. The working principle of the web edge sensor is as follows. Light from an array of infrared LEDs (or laser diodes) is projected on to the web surface. The light that intercepts the web get scattered in all direction and this scattered light is spatially filtered using the fiber optic elements within the sensor. The filtered light is then projected onto a camera sensor. The edge position is determined by processing the output of the camera sensor using sophisticated digital signal processing algorithms in real-time.



## Web Edge Sensor Specification



Four sensor widths that are currently available include 16 mm, 48 mm, 221 mm and 440 mm. The sensor head includes an infrared filter, a spatial filter based on fiber optics, a one dimensional camera sensor and infrared light source. The camera sensor has a resolution of 63.5 micron or 125 micron based on the sensor model. ARIS WPS 16 has 256 pixels while the ARIS WPS 48 has 768 pixels, both with 63.5 micron resolution. ARIS WPS 221 and WPS 440 have a resolution of 125 micron with 1792 and 3584 pixels respectively. The infrared LEDs have a peak wavelength of 850 nm. Because of the computational complexity the signal from the camera sensor needs to be processed with a dedicated sensor processing unit which is located remotely from the sensor head. Up to 10 m long cable can be used with the sensor head enabling remote installation of the sensor head from the sensor processing unit.



## Web Edge Sensor Performance: Experimental Procedure



The working principle of the web edge sensor enables the sensor to detect any type of material without any calibration. In this white paper we shown experiments with four type of materials (see Fig. 1) to highlight the sensor's ability to work with different materials. These materials include a (1) a low basis weight nonwoven web that is highly porous, (2) an optically black nonwoven web with low optical properties, (3) a clear film with low opacity, and (4) burlap a textile material which is significantly porous. All these materials are troublesome to existing sensing technologies because material properties significantly affect the amount of signal attenuation. An experimental setup (see Fig. 2) equipped with a high precision motor stage which moves the web material back and forth is used to quantify the sensor performance. The edge sensor is mounted on the experimental setup with an ability to change the working distance. Even though the sensor is design to work with web materials at an ideal working distance of 5 mm to 10 mm, the work distance is increased to 20 mm to understand the performance of the sensor. For the set of experiments with each web material, the web on the motor stage is moved back and forth (as shown in Fig. 3) several times during a experiment while the motor position data and sensor edge position data recorded.

 ![Sample web materials used in experiments](https://r2r.tech/sites/default/files/inline-images/WebSamples.png)![Motorized stage used in the web edge sensor performance quantification experiments](https://r2r.tech/sites/default/files/inline-images/experimental-setup.png)![The time domain plot of the motion of the motorized stage during the experiments.](https://r2r.tech/sites/default/files/inline-images/TimeDomainPlot.png)

## Sensor Performance: Experimental Results



Fig. 4 show representative sample of experimental results with 16 mm sensor for the four different web materials. Sixteen sets of data were collected positioning the motorstage to move back and forth eight times. The step size and the motor speed was chosen such that every single pixel is covered during every experiment. Data from all sixteen experiments are superimposed into a single plot. The abscissa shows the web displacement measured using the motor position sensor and the ordinate shows the web edge measured using our sensor. Both the axes are represented in millimeters. The blue dots in the plots are the actual measured data and the red dashed lines are the linear fit for each set of experiments. All the experiments showed excellent precision and accuracy of the sensor and sensing principle. As seen from the plots the accuracy (slope and bias), linearity, precision and repeatability of the sensing principle is unaffected by the material properties.

 ![Experimental results with the web edge sensor](https://r2r.tech/sites/default/files/inline-images/experimental-results.png)

The slope, bias and linearity of the measurement for the four sample materials are summarized in the table below. The slope of the edge sensor measurement, which is within 1.4% of the ideal slope of 1, as well as the non-zero bias of the measurement clearly shows the exceptional accuracy of the sensing principle. Note that the bias value is less than the resolution of the sensor, which is 0.0635 mm, which indicates the sensing principle doesn't affect the bias. The R-squared value, the quantification of the goodness of the fit, is close to one which shows that the measurement is highly reliable, linear and unaffected by the material properties.



| Web Material | Slope | Bias (mm) | R-squared |
| ------------ | ----- | --------- | --------- |
| Black Nonwoven Web | 1.00852 | 0.05013 | 0.99914 |
| Burlap Web | 1.04126 | 0.00238 | 0.99970 |
| Optically Transparent Web | 0.9950 | -0.05111 | 0.98326 |
| Low gsm Nonwoven | 1.01306 | 0.05218 | 0.99833 |



## Conclusion



The experimental results show, unlike conventional sensors, the material properties do not affect the accuracy and precision of the web edge sensor. The edge sensor accurately measures the edge position with opaque material, porous web material, nonwoven web material, transparent web material. Similar results are also seen with the 48 mm sensor. And similar results were also observed with other materials such as paper, plastics, foil and films.

---

# MC QD 1180-1181-1260

URL: https://r2r.tech/documentation/3d-models/mc-qd-1180-1181-1260.md

External motor Driver for high thrust actuators with SCU5 controller

---

# Motor Communication Cable

URL: https://r2r.tech/documentation/2d-drawings/motor-communication-cable.md

Motor Communication Cable

---

# Motor Controller - MC QD 1140/1141/1240/1241: 2D Drawing

URL: https://r2r.tech/documentation/2d-drawings/motor-controller-mc-qd-1140114112401241-2d-drawing.md

Motor Controller - MC QD 1140/1141/1240/1241: 2D Drawing

---

# Motor Controller - MC QD 1140/1141/1240/1241: 2D Drawing (DXF)

URL: https://r2r.tech/documentation/2d-drawings/motor-controller-mc-qd-1140114112401241-2d-drawing-dxf.md

Motor Controller - MC QD 1140/1141/1240/1241 2D Drawing (DXF)

---

# Motor Controller - MC QD 1180/1181/1211/1230/1231/1260: 2D Drawing

URL: https://r2r.tech/documentation/2d-drawings/motor-controller-mc-qd-118011811211123012311260-2d-drawing.md

Motor Controller - MC QD 1180/1181/1211/1230/1231/1260: 2D Drawing

---

# Motor Driver MC QD 1140/1141/1161/1180/1181/1211/1230/1231/1240/1260

URL: https://r2r.tech/documentation/manuals/motor-driver-mc-qd-1140114111611180118112111230123112401260.md

Motor Driver MC QD 1140/1141/1161/1180/1181/1211/1230/1231/1240/1260 Documentation

---

# Mounting Bracket for 1.5in or 40mm Extrusion for WPS, ODC and 1DC Sensors

URL: https://r2r.tech/documentation/3d-models/mounting-bracket-15in-or-40mm-extrusion-wps-odc-and-1dc-sensors.md

Mounting Bracket for 1.5" or 40 mm Extrusion for WPS, ODC and 1DC Sensors

---

# Mounting Bracket for 1in or 25mm Extrusion for WPS, ODC and 1DC Sensors

URL: https://r2r.tech/documentation/3d-models/mounting-bracket-1in-or-25mm-extrusion-wps-odc-and-1dc-sensors.md

### Mounting Bracket for 1" or 25 mm Extrusion for WPS, ODC and 1DC Sensors


 

---

# Narrow Web Steering Guides Product Brochure

URL: https://r2r.tech/documentation/brochures/narrow-web-steering-guides-product-brochure.md

Narrow Web Steering Guides Product Brochure

---

# New Mounting Brackets for WPS, ODC and 1DC sensors - 1.5 in or 40 mm extrusion

URL: https://r2r.tech/documentation/2d-drawings/new-mounting-brackets-wps-odc-and-1dc-sensors-15-or-40-mm-extrusion.md

New Mounting Brackets for WPS, ODC and 1DC sensors - 1.5 in or 40 mm extrusion

---

# New Mounting Brackets for WPS, ODC and 1DC sensors - 1in or 25 mm extrusion

URL: https://r2r.tech/documentation/2d-drawings/new-mounting-brackets-wps-odc-and-1dc-sensors-1in-or-25-mm-extrusion.md

New Mounting Brackets for WPS, ODC and 1DC sensors - 1in or 25 mm extrusion

---

# North American Web Guide - H5533 Actuator Replacement Kit

URL: https://r2r.tech/documentation/manuals/north-american-web-guide-h5533-actuator-replacement-kit.md

North American Web Guide - H5533 Actuator Replacement Kit

---

# ODC 192 xx-QD

URL: https://r2r.tech/documentation/2d-drawings/odc-192-xx-qd.md

ODC 192 xx-QD: 2D Drawing 

---

# ODC 192-xx QD

URL: https://r2r.tech/documentation/3d-models/odc-192-xx-qd.md

ODC 192-xx QD

---

# ODC 288-xx QD

URL: https://r2r.tech/documentation/3d-models/odc-288-xx-qd.md

ODC 288-xx QD

---

# ODC 384 xx-QD

URL: https://r2r.tech/documentation/2d-drawings/odc-384-xx-qd.md

ODC 384 xx-QD: 2D Drawing 

---

# ODC 384-xx QD

URL: https://r2r.tech/documentation/3d-models/odc-384-xx-qd.md

ODC 384-xx QD

---

# ODC 48 xx-QD: 2D Drawing 

URL: https://r2r.tech/documentation/2d-drawings/odc-48-xx-qd-2d-drawing.md

ODC 48 xx-QD: 2D Drawing 

---

# ODC 48-xx QD (1" Mounting w/Left Side Connector)

URL: https://r2r.tech/documentation/3d-models/odc-48-xx-qd-1-mounting-wleft-side-connector.md

### ODC 48-xx QD (1" Mounting w/Left Side Connector)


 

---

# ODC 48-xx QD (1" Mounting w/Right Side Connector)

URL: https://r2r.tech/documentation/3d-models/odc-48-xx-qd-1-mounting-wright-side-connector.md

ODC 48-xx QD (1" Mounting w/Right Side Connector)

---

# ODC 48-xx QD (No Mounting)

URL: https://r2r.tech/documentation/3d-models/odc-48-xx-qd-no-mounting.md

### ODC 48-xx QD (No Mounting)

---

# ODC 48-xx QD (NW 17 Rail)

URL: https://r2r.tech/documentation/3d-models/odc-48-xx-qd-nw-17-rail.md

ODC 48-xx QD (NW 17 Rail)

---

# ODC 48-xx QD w/1in Mounting Bracket

URL: https://r2r.tech/documentation/3d-models/odc-48-xx-qd-w1in-mounting-bracket.md

ODC 48-xx QD w/1in Mounting Bracket

---

# ODC 480 xx-QD: 2D Drawing 

URL: https://r2r.tech/documentation/2d-drawings/odc-480-xx-qd-2d-drawing.md

ODC 480 xx-QD: 2D Drawing 

---

# ODC 480-xx QD

URL: https://r2r.tech/documentation/3d-models/odc-480-xx-qd.md

ODC 480-xx QD

---

# ODC 768 xx-QD: 2D Drawing 

URL: https://r2r.tech/documentation/2d-drawings/odc-768-xx-qd-2d-drawing.md

ODC 768 xx-QD: 2D Drawing 

---

# ODC 768-xx QD

URL: https://r2r.tech/documentation/3d-models/odc-768-xx-qd.md

ODC 768-xx QD

---

# ODC 96 xx-QD

URL: https://r2r.tech/documentation/2d-drawings/odc-96-xx-qd.md

ODC 96 xx-QD: 2D Drawing 

---

# ODC 96-xx QD

URL: https://r2r.tech/documentation/3d-models/odc-96-xx-qd.md

ODC 96-xx QD

---

# ODC 960 xx-QD

URL: https://r2r.tech/documentation/2d-drawings/odc-960-xx-qd.md

ODC 960 xx-QD: 2D Drawing 

---

# ODC 960 xx-QD: 2D Drawing (dxf)

URL: https://r2r.tech/documentation/2d-drawings/odc-960-xx-qd-2d-drawing-dxf.md

ODC 960 xx-QD: 2D Drawing (dxf)

---

# ODC 960-xx QD

URL: https://r2r.tech/documentation/3d-models/odc-960-xx-qd.md

ODC 960-xx QD

---

# ODC and WPS Installation for Center Guiding and Web Width Measurement

URL: https://r2r.tech/documentation/manuals/odc-and-wps-installation-center-guiding-and-web-width-measurement.md

ODC 96/192/288/384/480/768/960 or WPS 112/221/440/900 Sensor Installation for Center Guiding and Web Width Measurement

---

# Power Supply Regen Clamp Wiring

URL: https://r2r.tech/documentation/wiring-diagrams/power-supply-regen-clamp-wiring.md

Power Supply Regen Clamp Wiring

---

# PROFINET GSDML File for SCU5 firmware Version 3.5+ using Hilscher Module

URL: https://r2r.tech/documentation/support-files/profinet-gsdml-file-scu5-firmware-version-35-using-hilscher-module.md

PROFINET GSDML File for SCU5 firmware Version 3.5+ using Hilscher Module

---

# PROFINET GSDML File for SCU5 firmware Version 3.5+ using HMS Module

URL: https://r2r.tech/documentation/support-files/profinet-gsdml-file-scu5-firmware-version-35-using-hms-module.md

PROFINET GSDML File for SCU5 firmware Version 3.5+ using HMS Module

---

# Quick Disconnect Sensor Cable (Murr 7000-53301-7060500)

URL: https://r2r.tech/documentation/product-sheets/quick-disconnect-sensor-cable-murr-7000-53301-7060500.md

Quick Disconnect Sensor Cable (Murr 7000-53301-7060500)

---

# Quick Disconnect Sensor Cable (Phoenix Contact 1402551)

URL: https://r2r.tech/documentation/product-sheets/quick-disconnect-sensor-cable-phoenix-contact-1402551.md

Quick Disconnect Sensor Cable (Phoenix Contact 1402551)

---

# Quick Disconnect Sensor Cable (Turck RKS 12T-x-RSS 12T)

URL: https://r2r.tech/documentation/2d-drawings/quick-disconnect-sensor-cable-turck-rks-12t-x-rss-12t.md

Quick Disconnect Sensor Cable (Turck RKS 12T-x-RSS 12T)

---

# Quick Disconnect Sensor Cable (Turck WKS 12T-x-RSS 12T)

URL: https://r2r.tech/documentation/2d-drawings/quick-disconnect-sensor-cable-turck-wks-12t-x-rss-12t.md

Quick Disconnect Sensor Cable (Turck WKS 12T-x-RSS 12T)

---

# Register Map for 1DC Series Roll-2-Roll® Sensor (v 4.3a+)

URL: https://r2r.tech/documentation/manuals/register-map-1dc-series-roll-2-rollr-sensor-v-43a.md

Register Map for 1DC Series Roll-2-Roll® Sensor (v 4.3a+)

---

# Remote Touch Screen Operator Interface (RTI) User Manual

URL: https://r2r.tech/documentation/manuals/remote-touch-screen-operator-interface-rti-user-manual.md

Remote Touch Screen Operator Interface (RTI) User Manual

---

# Retrofit Actuator - LHS-0xx-xxxx-TG: 2D Drawing (DXF)

URL: https://r2r.tech/documentation/2d-drawings/retrofit-actuator-lhs-0xx-xxxx-tg-2d-drawing-dxf.md

Retrofit actuator with front rod eye and rear eye.

---

# Retrofit Installation Checklist

URL: https://r2r.tech/documentation/manuals/retrofit-installation-checklist.md

******Controller Installation**



- 24 VDC power supply with a minimum of 5 Amps is supplied by Roll-2-Roll Technologies or available from customer. Suggested power supplies: Mean Well  SDR-120-24 or SDR-240-24
- 24 VDC power supply cable with connector is supplied by Roll-2-Roll Technologies or available from customer.



**Suggested alternative to factory supplied cable: Switchcraft [CA761KS07984](https://www.mouser.com/ProductDetail/Switchcraft/CA761KS07984?qs=YEulNHxZQDNnPC0BYAaQ3g%3D%3D) or [CARA761KS07984](https://www.mouser.com/ProductDetail/Switchcraft/CARA761KS07984?qs=YEulNHxZQDOQr74DaUOhXA%3D%3D)**



- Length of the power cable is sufficient to connect the power supply in the cabinet to the SCU5 controller/operator interface installed at a desired location for operation.
- The SCU5 controller case is grounded to the protective earth or the earthed ground. The mounting holes or the mounting brackets are used to make proper protective earth connection.
- The red wire is connected to +V (+24 VDC) and black wire is connected to -V (GND) on the DC side of the power supply. The red and black wires are for the cables supplied by Roll-2-Roll Technologies.
- When the power supply is connected to the SCU5 controller, the operator interface powers up and the communication indicator or the heartbeat is blinking on the controller screen.



**Sensor Installation**



- The sensor mounting rail is supplied with the sensor or is available: Low Profile Sensor Rail or 1” Sensor Mounting Rail
- The sensor slides freely in the rail and can be locked in a desired position on the rail with a brake or a thumbscrew.
- The sensor mounting rail is long enough for the desired application, especially when the web width changes.
- The sensor cable is long enough for the desired sensor location and the SCU5 controller location.



**Suggested cable extensions: Turck [RKS 12t-5-RSS 12 T](https://www.alliedelec.com/m/d/68268c18dbcb83153cc51b571f8b59bf.pdf) or Phoenix Contact [SAC-12P-MS/5,0-35T/FS SH SCO](https://www.phoenixcontact.com/pxc-oc-itemdetail-pdf-web/eshop?lineItemType=LineItem&UID=1404940)**



- The sensor or the sensor cable does not appear to be damaged.
- After connecting the sensor(s) to the controller and turning ON the power supply, the sensor(s) detect/measure the position of a material in its field of view. The web position is indicated on the operator interface and the web detect LED lights up for the sensor(s).
- Edge and Center Guiding:   For all applications, except contrast guiding application, the infrared sensor is mounted in a free span between two rollers. No object is present within 150 mm or 6 inches from the field of view of the sensor except the web itself. The sensor is within 5 mm to 15 mm (0.2 in to 0.6 in) from the web.
- For edge or center guiding applications the sensor is installed downstream of the exit roller of the web guide. The sensor is installed within the first one-third or one-half of the exit span. Additionally, the location of the sensor is such that the plane change due to normal guiding action will maintain the web at a distance of 5 mm to 30 mm (0.2 to 1.25 in) from the sensor at all times. An additional backup roller may be installed to reduce the plane change effect.



**Contrast Guiding: **



- For contrast guiding, line guiding and other contrast sensing application, the white light sensor is installed at a distance of 5 mm (0.2 in) from the web. The web in the field of view of the sensor is supported on a backup roller so that the web is stabilized to prevent any plane change or flutter.
- The sensor and the backup roller are installed downstream of the web guide within the first one-third or one-half of the exit span. The wrap angle of the web on the backup roller is no more than 20 degrees.



**Unwind Guiding:**



- For unwind guiding the sensor is installed downstream of the idler roller that is mounted on the lateral shifting unwind.



**Rewind Guiding:**



- For rewind guiding (or chasing) the sensor is installed upstream of the fixed idler before the rewind. The sensor is mounted on the lateral shifting rewind stand.



**Use the [sensor installation recommendation](https://r2r.tech/documentation/sensor-installation-recommendations) to finalize the location and position of the sensor.**



**Retrofit Actuator Installation**



- Checking the existing guide structure:   The existing guide structure is in good working condition and the roller bearings are good without any movement due to bearing wear.
- A detailed dimensional sketch or a photograph of the way in which the existing actuator is mounted on the guide structure is recorded.
- The way in which the actuator connected to the machine frame and the moving guide structure is noted.
- The existing old actuator is disconnected and all parts are appropriately marked and saved.
- The guide structure, without the actuator connected, moves freely through its full range of motion without binding.
- The guide structure can be easily pushed by hand without much effort.
- If there is any binding the bearing can be cleaned or replaced to prevent any binding.



**Checking the functionality of the new actuator:**



- Without installing the new actuator onto the old guide structure the actuator functionality is checked by connecting the communication cable, the actuator cable, and the power cable to the respective ports on the SCU5 controller, the motor driver and the actuator before power is applied.
- When the Roll-2-Roll 24 VDC power is turned on to the SCU5 controller, the Jog operations on the SCU5 controller moves the actuator back and forth.



**Installing the actuator with fixed mounting option: **



- If the old actuator has fixed mounting options (bolted directly to the machine frame), a new mounting plate is available to appropriately mount the new actuator from Roll-2-Roll to the machine frame.  
- The new actuator is mounted so that the linear motion of the actuator is exactly inline and aligned with the motion of the moving carriage on the existing guide structure rails.
- The front end of the Roll-2-Roll actuator is mounted to the moving frame with threaded screws or bolts or with pivot pins similar to the old actuator. If pivot pin is used then the orientation of the pin with respect to the stroke of the actuator in the new installation is same as the old actuator installation. If the actuator is directly screwed then thread lockers are used to prevent rotation of the leadscrew.



**Installing the actuator floating mounting option: **



- If the old actuator has a floating mounting option such as a rear clevis or a rear pivot or a rear spherical rod eye, the new actuator from Roll-2-Roll has the same or similar option.
- The front end of the Roll-2-Roll actuator is mounted to the moving frame with a front clevis rod end or a spherical rod end. The pivot pin is orientated in the same direction as the old actuator installation.
- The rear end of the Roll-2-Roll actuator is mounted to the machine frame with a rear clevis or a rear pivot eye or a rear rod eye with the pivot pin in the same orientation as the old actuator installation.
- If the actuators do not have an anti-rotation provision on the actuator, then an anti-rotation mounting is installed during the installation, especially with spherical front and rear rod eyes.
- The extension and retraction of the actuator allows the actuator to rotate on the front and rear pins for automatic alignment.



**Checking the actuator installation:**



- After reconnecting the actuator cable to motor driver and turning ON the SCU5 controller, the guide structure moves when jogged. The actuator does not struggle to move the guide structure.
- The actuator is mounted such that the fully retracted and fully extended position of the actuator coincides with the extreme positions of the moving frame on the guide structure.
- If the actuator stroke is more than the stroke available on the guide structure, the digital stroke length of the actuator is reduced to match the physical stroke available on the guide structure.
- If the actuator stroke is less than the stroke length available on the guide structure, appropriate mechanical stops are installed to match the actuator stroke length.
- The actuator is installed so that the center of stroke of the actuator and the center of stroke of the linear raceway match.



**Installing the servo center sensor: **



- If a servo center sensor is installed on the actuator then the position of the servo center sensor is moved such that the guide structure is in the middle of its stroke.
- The servo center sensor is installed directly on the guide structure then the sensor is installed such that it sees a metal surface (within 2 mm from the servo center sensor) for one half of the stroke and free space for the other half of the stroke.
- Jogging the actuator back and forth lights ON and OFF the LED on the servo center sensor. The transition between ON and OFF occurs at the middle stroke position of the guide structure.



**Checking the retrofit installation: **



- The Jog functionality on the SCU5 controller moves the guide structure back and forth.
- The servo center functionality on the SCU5 controller centers the guide structure at the middle position of the guide structure.
- With the sensor connected to the SCU5 controller, the automatic functionality moves the actuator based on the web position.
- The actuator polarity is set such that the web guide moves to position the web to the guide point on the sensor. If not the actuator polarity is reversed.

---

# RLA-050-0600-TG

URL: https://r2r.tech/documentation/3d-models/rla-050-0600-tg.md

RLA-050-0600-TG

---

# RLA-050-0600-TG: 2D Drawing (pdf)

URL: https://r2r.tech/documentation/2d-drawings/rla-050-0600-tg-2d-drawing-pdf.md

RLA-050-0600-TG: 2D Drawing (pdf)

---

# Rockwell/AB Add-on Instructions for 1DC Series of Roll-2-Roll® Sensor

URL: https://r2r.tech/documentation/support-files/rockwellab-add-instructions-1dc-series-roll-2-rollr-sensor.md

Rockwell/AB Add-on Instructions for 1DC Series of Roll-2-Roll® Sensor

---

# Rockwell/AB Add-on Instructions for SCU5 C(E)D/MC(E)D controller v3.5d

URL: https://r2r.tech/documentation/support-files/rockwellab-add-instructions-scu5-cedmced-controller-v35d.md

Rockwell/AB Add-on Instructions for SCU5 C(E)D/MC(E)D controller v3.5d

---

# Rockwell/AB Add-on Instructions for SCU5 C(E)D/MC(E)D controller v3.6c

URL: https://r2r.tech/documentation/support-files/rockwellab-add-instructions-scu5-cedmced-controller-v36c.md

Rockwell/AB Add-on Instructions for SCU5 C(E)D/MC(E)D controller v3.6c

---

# Rockwell/AB Add-on Instructions for SCU5 C(E)D/MC(E)D controller v3.6g

URL: https://r2r.tech/documentation/support-files/rockwellab-add-instructions-scu5-cedmced-controller-v36g.md

Rockwell/AB Add-on Instructions for SCU5 C(E)D/MC(E)D controller v3.6g

---

# Rockwell/AB Add-on Instructions for SCU5 C(E)D/MC(E)D controller v3.6i

URL: https://r2r.tech/documentation/support-files/rockwellab-add-instructions-scu5-cedmced-controller-v36i.md

Rockwell/AB Add-on Instructions for SCU5 C(E)D/MC(E)D controller v3.6i

---

# Rockwell/AB Add-on Instructions for SCU5 C(E)D/MC(E)D controller v3.6l

URL: https://r2r.tech/documentation/support-files/rockwellab-add-instructions-scu5-cedmced-controller-v36l.md

Rockwell/AB Add-on Instructions for SCU5 C(E)D/MC(E)D controller v3.6l

---

# Rockwell/AB Add-on Instructions for SCU6x C(E)D/MC(E)D controller v4.1+

URL: https://r2r.tech/documentation/support-files/rockwellab-add-instructions-scu6x-cedmced-controller-v41.md

Rockwell/AB Add-on Instructions for SCU6x C(E)D/MC(E)D controller v4.1+

---

# Roll-2-Roll Technologies Product Brochure 2020 - Web Guiding Systems, Sensors and Controllers

URL: https://r2r.tech/documentation/brochures/roll-2-roll-technologies-product-brochure-2020-web-guiding-systems-sensors.md

A four page brochure with general information on products and applications for web guiding, monitoring and control

---

# Roll-2-Roll® Actuators Brochure

URL: https://r2r.tech/documentation/brochures/roll-2-rollr-actuators-brochure.md

Roll-2-Roll® Actuators Brochure

---

# Roll-2-Roll® Control Center Pro Software (Windows)

URL: https://r2r.tech/documentation/software/roll-2-rollr-control-center-pro-software-windows.md

[Roll-2-Roll® Control Center Pro Software (Windows)](https://drive.google.com/file/d/1UWERQZ31YF4CaOAp_ei6l-SoH3jOgUJA/view?usp=sharing)

![Roll-2-Roll Logo](https://r2r.tech/sites/default/files/inline-images/R2R_Logo.png)

---

# Roll-2-Roll® Control Center Software (Windows)

URL: https://r2r.tech/documentation/software/roll-2-rollr-control-center-software-windows.md

[Click this link to download the Roll-2-Roll® Control Center Software](https://drive.google.com/file/d/1KZbYN6EqjBs5QZGAfep9VsOuti0DYeqc/view?usp=drive_link) (Windows)

![Roll-2-Roll Logo](https://r2r.tech/sites/default/files/inline-images/R2R_Logo.png)

---

# Roll-2-Roll® Controller Product Brochure

URL: https://r2r.tech/documentation/brochures/roll-2-rollr-controller-product-brochure.md

Roll-2-Roll® Controller Product Brochure

---

# Roll-2-Roll® Sensor: ODC Product Brochure

URL: https://r2r.tech/documentation/brochures/roll-2-rollr-sensor-odc-product-brochure.md

Roll-2-Roll® Sensor: ODC Product Brochure

---

# Roll-2-Roll® Sensor: WPS 440 Product Brochure

URL: https://r2r.tech/documentation/brochures/roll-2-rollr-sensor-wps-440-product-brochure.md

Roll-2-Roll® Sensor: WPS 440 Product Brochure

---

# Roll-2-Roll® Sensor: WPS 900 Product Brochure

URL: https://r2r.tech/documentation/wps-900-product-brochure.md

Roll-2-Roll® Sensor: WPS 900 Product Brochure

---

# Roll-2-Roll® Sensor: WPS Product Brochure

URL: https://r2r.tech/documentation/brochures/roll-2-rollr-sensor-wps-product-brochure.md

Roll-2-Roll® Sensor: WPS Product Brochure

---

# Roll-2-Roll® Upgrade Kit: Product Brochure

URL: https://r2r.tech/documentation/brochures/roll-2-rollr-upgrade-kit-product-brochure.md

Roll-2-Roll® Upgrade Kit: Product Brochure

---

# Roll-2-Roll® Web Guide Upgrade Kit Product Brochure

URL: https://r2r.tech/documentation/brochures/roll-2-rollr-web-guide-upgrade-kit-product-brochure.md

Roll-2-Roll® Web Guide Upgrade Kit Product Brochure

---

# Roll-2-Roll® Web Guides: Product Brochure

URL: https://r2r.tech/documentation/brochures/roll-2-rollr-web-guides-product-brochure.md

Roll-2-Roll® Web Guides: Product Brochure

---

# RTI + SCU5 C(E)D Wiring with 2x ODC for Web Width Measurement

URL: https://r2r.tech/documentation/wiring-diagrams/rti-scu5-ced-wiring-2x-odc-web-width-measurement.md

RTI + SCU5 C(E)D Wiring with 2x ODC for Web Width Measurement

---

# RTI + SCU5 C(E)D Wiring with 2x ODC for Web Width Measurement with Stacklight

URL: https://r2r.tech/documentation/wiring-diagrams/rti-scu5-ced-wiring-2x-odc-web-width-measurement-stacklight.md

RTI + SCU5 C(E)D Wiring with 2x ODC for Web Width Measurement with Stacklight

---

# RTI + SCU5 MC(E)D Wiring with MC QD 1140/1141/1240 with Retrofit Actuator

URL: https://r2r.tech/documentation/wiring-diagrams/rti-scu5-mced-wiring-mc-qd-114011411240-retrofit-actuator.md

RTI + SCU5 MC(E)D Wiring with MC QD 1140/1141/1240 with Retrofit Actuator

---

# SCU5

URL: https://r2r.tech/documentation/3d-models/scu5.md

SCU5

---

# SCU5 C(x)D Wiring with ODC (Industrial Ethernet)

URL: https://r2r.tech/documentation/wiring-diagrams/scu5-cxd-wiring-odc-industrial-ethernet.md

SCU5 C(x)D Wiring with ODC (Industrial Ethernet)

---

# SCU5 C(x)D Wiring with WPS Sensor (Industrial Ethernet)

URL: https://r2r.tech/documentation/wiring-diagrams/scu5-cxd-wiring-wps-sensor-industrial-ethernet.md

SCU5 C(x)D Wiring with WPS Sensor (Industrial Ethernet)

---

# SCU5 Controller: 2D Drawing (DXF)

URL: https://r2r.tech/documentation/2d-drawings/scu5-controller-2d-drawing-dxf.md

SCU5 D/MD/MC(E)D Controller 2D Drawing (DXF)

---

# SCU5 Controller: 2D Drawing (pdf)

URL: https://r2r.tech/documentation/2d-drawings/scu5-controller-2d-drawing-pdf.md

SCU5 D/MD/MC(E)D Controller 2D Drawing

---

# SCU5 D Wiring with ODC (Analog Output)

URL: https://r2r.tech/documentation/wiring-diagrams/scu5-d-wiring-odc-analog-output.md

SCU5 D Wiring with ODC (Analog Output)

---

# SCU5 D Wiring with WPS Sensor (Analog Output)

URL: https://r2r.tech/documentation/wiring-diagrams/scu5-d-wiring-wps-sensor-analog-output.md

SCU5 D Wiring with WPS Sensor (Analog Output)

---

# SCU5 DD Opto-Isolated Output Documentation

URL: https://r2r.tech/documentation/manuals/scu5-dd-opto-isolated-output-documentation.md

SCU5 DD Opto-Isolated Output Documentation

---

# SCU5 DD Wiring with ODC (Digital Output)

URL: https://r2r.tech/documentation/wiring-diagrams/scu5-dd-wiring-odc-digital-output.md

SCU5 DD Wiring with ODC (Digital Output)

---

# SCU5 DD Wiring with WPS Sensor (Digital Output)

URL: https://r2r.tech/documentation/wiring-diagrams/scu5-dd-wiring-wps-sensor-digital-output.md

SCU5 DD Wiring with WPS Sensor (Digital Output)

---

# SCU5 DI Wiring with ODC (Digital Input and Output)

URL: https://r2r.tech/documentation/wiring-diagrams/scu5-di-wiring-odc-digital-input-and-output.md

SCU5 DI Wiring with ODC (Digital Input and Output)

---

# SCU5 DI Wiring with WPS Sensor (Digital Input and Output)

URL: https://r2r.tech/documentation/wiring-diagrams/scu5-di-wiring-wps-sensor-digital-input-and-output.md

SCU5 DI Wiring with WPS Sensor (Digital Input and Output)

---

# SCU5 M: Web Guide Controller Product and User Manual (V2.6)

URL: https://r2r.tech/documentation/manuals/scu5-m-web-guide-controller-product-and-user-manual-v26.md

This is the product and user manual for the SCU5 M web guide controller firmware version 2.6 and later.

---

# SCU5 MC(x)D Wiring with MC QD 1141/1140/1240 + Web Guide Actuator

URL: https://r2r.tech/documentation/wiring-diagrams/scu5-mcxd-wiring-mc-qd-114111401240-web-guide-actuator.md

SCU5 MC(x)D Wiring with MC QD 1141/1140/1240 + Web Guide Actuator

---

# SCU5 MD Wiring with MC QD 1141/1140/1240 + Web Guide Actuator

URL: https://r2r.tech/documentation/wiring-diagrams/scu5-md-wiring-mc-qd-114111401240-web-guide-actuator.md

SCU5 MD Wiring with MC QD 1141 + Web Guide Actuator

---

# SCU5 MD Wiring with MC QD 1180/1181/1211/1230/1231/1260 + Large Upgrade Actuator

URL: https://r2r.tech/documentation/wiring-diagrams/scu5-md-wiring-mc-qd-118011811211123012311260-large-upgrade-actuator.md

SCU5 MD Wiring with MC QD 1180/1181/1211/1230/1231/1260 + Large Upgrade Actuator

---

# SCU5 MD Wiring with MC QD 1180/1181/1211/1230/1231/1260 + Regen Clamp + Unwind/Rewind Actuator

URL: https://r2r.tech/documentation/wiring-diagrams/scu5-md-wiring-mc-qd-118011811211123012311260-regen-clamp.md

SCU5 MD Wiring with MC QD 1180/1181/1211/1230/1231/1260 + Regen Clamp + Unwind/Rewind Actuator

---

# SCU5 MD Wiring with MC QD 1180/1181/1211/1230/1231/1260 + Web Guide Actuator

URL: https://r2r.tech/documentation/wiring-diagrams/scu5-md-wiring-mc-qd-118011811211123012311260-web-guide-actuator.md

SCU5 MD Wiring with MC QD 1180/1181/1211/1230/1231/1260 + Web Guide Actuator

---

# SCU5 MD Wiring with ODC Sensor, MC QD 1140/1141/1240 with Web Guide

URL: https://r2r.tech/documentation/wiring-diagrams/scu5-md-wiring-odc-sensor-mc-qd-114011411240-web-guide.md

SCU5 MD Wiring with ODC Sensor, MC QD 1140/1141/1240 with Web Guide

---

# SCU5 MDIO Wiring with MC QD 1141/1140/1240 + Web Guide Actuator

URL: https://r2r.tech/documentation/wiring-diagrams/scu5-mdio-wiring-mc-qd-114111401240-web-guide-actuator.md

SCU5 MDIO Wiring with MC QD 1141/1140/1240 + Web Guide Actuator

---

# SCU5 MDIO: Digitial Input and Output Documentation

URL: https://r2r.tech/documentation/manuals/scu5-mdio-digitial-input-and-output-documentation.md

SCU5 MDIO: Digitial Input and Output Documentation

---

# SCU5 xC(x)D Register Map for v3.5

URL: https://r2r.tech/documentation/manuals/scu5-xcxd-register-map-v35.md

SCU5 xC(x)D Register Map for v3.5

---

# SCU5 xC(x)D Register Map for v3.6

URL: https://r2r.tech/documentation/manuals/scu5-xcxd-register-map-v36.md

SCU5 xC(x)D Register Map for v3.6a, v3.6b and v3.6c

---

# SCU5 xC(x)D Register Map for v3.6d

URL: https://r2r.tech/documentation/manuals/scu5-xcxd-register-map-v36d.md

SCU5 xC(x)D Register Map for v3.6d

---

# SCU5 xC(x)D Register Map for v3.6g

URL: https://r2r.tech/documentation/manuals/scu5-xcxd-register-map-v36g.md

SCU5 xC(x)D Register Map for v3.6g

---

# SCU5 xC(x)D Register Map for v3.6i

URL: https://r2r.tech/documentation/manuals/scu5-xcxd-register-map-v36i.md

SCU5 xC(x)D Register Map for v3.6i

---

# SCU5: Sensor and Web Guide Controller User Manual v3.3

URL: https://r2r.tech/documentation/manuals/scu5-sensor-and-web-guide-controller-user-manual-v33.md

This is the product and user manual for the SCU5 Sensor and Web Guide Controller firmware version 3.3.

---

# SCU5: Sensor and Web Guide Controller User Manual v3.4

URL: https://r2r.tech/documentation/manuals/scu5-sensor-and-web-guide-controller-user-manual-v34.md

This is the product and user manual for the SCU5 Sensor and Web Guide Controller firmware version 3.4.

---

# SCU5: Sensor and Web Guide Controller User Manual v3.6

URL: https://r2r.tech/documentation/manuals/scu5-sensor-and-web-guide-controller-user-manual-v36.md

SCU5: Sensor and Web Guide Controller User Manual v3.6

---

# SCU5: Sensor and Web Guide Controller User Manual v3.6d+

URL: https://r2r.tech/documentation/manuals/scu5-sensor-and-web-guide-controller-user-manual-v36d.md

SCU5: Sensor and Web Guide Controller User Manual v3.6d+

---

# SCU5: Sensor and Web Guide Controller User Manual v3.6n+

URL: https://r2r.tech/documentation/manuals/scu5-sensor-and-web-guide-controller-user-manual-v36n.md

SCU5: Sensor and Web Guide Controller User Manual v3.6n+

---

# SCU6x

URL: https://r2r.tech/documentation/3d-models/scu6x.md

SCU6x: 3D Model (STEP)

---

# SCU6x Industrial Ethernet Register Map for v4.1+

URL: https://r2r.tech/documentation/manuals/scu6x-industrial-ethernet-register-map-v41.md

SCU6x Industrial Ethernet Register Map for v4.1+

---

# SCU6x MD Wiring Diagram with Retrofit/Upgrade Actuator

URL: https://r2r.tech/documentation/wiring-diagrams/scu6x-md-wiring-diagram-retrofitupgrade-actuator.md

SCU6x MD Wiring Diagram with Retrofit/Upgrade Actuator

---

# SCU6x MD Wiring Diagram with Web Guide

URL: https://r2r.tech/documentation/wiring-diagrams/scu6x-md-wiring-diagram-web-guide.md

SCU6x MD Wiring Diagram with Web Guide

---

# SCU6x MxD Wiring Diagram with Unwind/Rewind (Small Load)

URL: https://r2r.tech/documentation/wiring-diagrams/scu6x-mxd-wiring-diagram-unwindrewind-small-load.md

SCU6x MxD Wiring Diagram with Unwind/Rewind (Small Load)

---

# SCU6x MxD Wiring Diagram with Unwind/Rewind Actuator

URL: https://r2r.tech/documentation/wiring-diagrams/scu6x-mxd-wiring-diagram-unwindrewind-actuator.md

SCU6x MxD Wiring Diagram with Unwind/Rewind Actuator

---

# SCU6x MxD Wiring Diagram with Unwind/Rewind Actuator with Regen Clamp

URL: https://r2r.tech/documentation/wiring-diagrams/scu6x-mxd-wiring-diagram-unwindrewind-actuator-regen-clamp.md

SCU6x MxD Wiring Diagram with Unwind/Rewind Actuator with Regen Clamp

---

# SCU6x MxD Wiring Diagram with Unwind/Rewind Actuator without Regen Clamp

URL: https://r2r.tech/documentation/wiring-diagrams/scu6x-mxd-wiring-diagram-unwindrewind-actuator-without-regen-clamp.md

SCU6x MxD Wiring Diagram with Unwind/Rewind Actuator without Regen Clamp

---

# SCU6x Product Brochure

URL: https://r2r.tech/documentation/brochures/scu6x-product-brochure.md

SCU6x Product Brochure

---

# SCU6x Wiring with ODC Sensors

URL: https://r2r.tech/documentation/wiring-diagrams/scu6x-wiring-odc-sensors.md

SCU6x Wiring with ODC Sensors

---

# SCU6x: 2D Drawing (pdf)

URL: https://r2r.tech/documentation/2d-drawings/scu6x-2d-drawing-pdf.md

SCU6x: 2D Drawing (pdf)

---

# SCU6x: 2D Drawing Front View (dxf)

URL: https://r2r.tech/documentation/2d-drawings/scu6x-2d-drawing-front-view-dxf.md

SCU6x: 2D Drawing Front View (dxf)

---

# SCU6x: 2D Drawing SCUx Connectors (dxf)

URL: https://r2r.tech/documentation/2d-drawings/scu6x-2d-drawing-scux-connectors-dxf.md

SCU6x: 2D Drawing SCUx Connectors (dxf)

---

# SCU6x: Sensor and Web Guide Controller User Manual

URL: https://r2r.tech/documentation/manuals/scu6x-sensor-and-web-guide-controller-user-manual.md

SCU6x: Sensor and Web Guide Controller User Manual

---

# SDR-120-24 AC-DC Industrial DIN rail power supply; Output 24Vdc at 5A; Metal casing; Ultra slim width 40mm

URL: https://r2r.tech/documentation/product-sheets/sdr-120-24-ac-dc-industrial-din-rail-power-supply-output-24vdc-5a.md

SDR-120-24 AC-DC Industrial DIN rail power supply; Output 24Vdc at 5A; Metal casing; Ultra slim width 40mm

---

# SDR-75-24 AC-DC Industrial DIN rail power supply; Output 24Vdc at 3.2A; Metal casing; Ultra slim width 32mm

URL: https://r2r.tech/documentation/product-sheets/sdr-75-24-ac-dc-industrial-din-rail-power-supply-output-24vdc-32a.md

SDR-75-24 AC-DC Industrial DIN rail power supply; Output 24Vdc at 3.2A; Metal casing; Ultra slim width 32mm

---

# Sealed Power Jack, 0.10" (2.5mm) center pin, Solder Lugs

URL: https://r2r.tech/documentation/2d-drawings/sealed-power-jack-010-25mm-center-pin-solder-lugs.md

Sealed Power Jack, 0.10" (2.5mm) center pin, Solder Lugs

---

# Sensor for Line Guiding and Contrast Guiding Applications

URL: https://r2r.tech/documentation/white-papers/sensor-line-guiding-and-contrast-guiding-applications.md

## Introduction



[ARIS Web Position Sensor](http://www.r2r-tech.com/products/aris-wps-16-ir) (WPS) can use either infrared (IR) light or white light (WL) to detect the position of a web material. As a contrast sensor ARIS WPS with WL option can detect visible contrasts on the web. The [revolutionary sensor technology](http://r2r.tech/articles/new-web-position-or-web-edge-sensor) is based on spatial filtering of light to accurately determine the position of a contrast edge or line on the web material, irrespective of the material properties. This sensing principle is unique and provides a true, absolute position measurement.



The working principle of the sensor is as follows. Light from an array of white LEDs is projected on to the web surface. The light that intercepts the web get scattered in all direction and this scattered light is spatially filtered using the fiber optic array within the sensor. The filtered light is then projected onto a camera sensor. The position of the edge, which is defined by the contrast between the two web layers, is determined by processing the output of the camera sensor using sophisticated digital signal processing algorithms in real-time. The algorithm automatically adjusts for the contrasts and is unaffected by the ambient lighting conditions. Essentially the sensor calibrates itself continuously.



## Contrast Sensor Specification



Three sensor widths that are currently available with the WL option include 16 mm, 48 mm and 221 mm. The sensor head includes a light diffuser, a spatial optical filter, a 1D camera sensor and white LED light source. Depending on the width, the 1D camera sensor resolution is either 63.5 micron or 125 micron. The image captured by the 1D camera sensor is transferred to a dedicated sensor processing unit to compute the output. Up to 10 m long cable can be used with the sensor head enabling remote installation of the sensor head from the sensor processing unit.



## Contrast Sensor Performance: Experimental Procedure



In this white paper, we shown experiments with four types of composite webs with different substrates (see Fig. 1) to [highlight the contrast sensor's ability to work with different materials](https://www.youtube.com/watch?v=q0s_qIp3thA) with different contrast properties. The composite web consists of a clear carrier film that supports the printed label web. Three substrates with varied optical properties are used for the printed label web. These substrates are white, metallic and clear. The printing on the four labels are also different and the contrast between different labels are substantially different. The contrast sensor measures the position of the die cut edge of the label. The contrast difference between the clear carrier film and the printed label substrate is the edge of interest. Common issues with these substrates on a clear carrier film are mainly the low contrast levels between the substrate, the contrast difference within the labels and the carrier film, and the reflective properties of the substrate. The experimental results show the effectiveness of the signal processing algorithm to overcome these limitations.

 ![Web material samples with contrasting features on the web](https://r2r.tech/sites/default/files/inline-images/Contrast-web-examples.png)

An experimental setup (see Fig. 2), equipped with a high precision motor stage which moves the web material back and forth, is used to quantify the sensor performance. For each set of experiments with each sample, the web on the motor stage is moved back and forth (as shown in Fig. 3) several times during a experiment while the motor position data and sensor edge position data are recorded.

 ![Experimental setup with contrast sensor installed on a motorized stage](https://r2r.tech/sites/default/files/inline-images/ExperimentalSetup.png)![The time domain plot of the motion of the motorized stage during the experiments.](https://r2r.tech/sites/default/files/inline-images/TimeDomainPlot_0.png)

## Contrast Sensor Performance: Experimental Results



Fig. 4 show representative sample of experimental results with 16 mm sensor for the four different samples. Six sets of data were collected by positioning the motor stage to move back and forth three times. The step size and the motor speed was chosen such that every single pixel is covered during every experiments. Data from all six experiments are superimposed into a single plot. The abscissa shows the web displacement measured using the motor position sensor and the ordinate shows the web edge measured using our sensor. Both the axes are represented in millimeters. The blue dots in the plots are the actual measured data and the red dashed line is the linear fit for each set of experiment. The table shows the parameters for the linear fit to the data from each experiment. All the experiments showed excellent [precision, accuracy and linearity of the sensor](http://www.r2r-tech.com/articles/accuracy-precision-linearity-and-resolution-web-guiding-understanding-terminology) (and the sensing principle) irrespective of the optical properties of the substrate. No calibration or any type of adjustment was made to the contrast sensor between any of these experiments. Moreover, the ambient light conditions did not affect the sensor accuracy, precision or linearity.

 ![Experimental results with the contrast sensor](https://r2r.tech/sites/default/files/inline-images/contrast-sensing-experimental-results.png)

The slope, bias and linearity of the measurement for the four sample materials are summarized in the table below. The slope of the sensor measurement, which is within 0.2% of the ideal slope of 1, as well as the non-zero bias of the measurement clearly shows the exceptional accuracy of the sensing principle. Note that the bias value is less than the resolution of the sensor, which is 0.0635 mm, which indicate that the bias is also unaffected by the sensing principle. The R-squared value, the quantification of the goodness of the fit, is close to one which shows that the measurement is highly reliable, linear and unaffected by the material properties.



| Web Material | Slope | Bias (mm) | R-squared |
| ------------ | ----- | --------- | --------- |
| Label 1 | 1.00484 | 0.04351 | 0.99962 |
| Label 2 | 1.00809 | 0.05035 | 0.99981 |
| Label 3 | 1.00961 | 0.01856 | 0.99982 |
| Label 4 | 0.99834 | 0.06170 | 0.99946 |



## Conclusion



The experimental results show the accuracy and precision of the contrast sensor are unaffected by the material properties unlike conventional sensors. The contrast sensor accurately measures the edge position (defined by the contrast between the materials) irrespectively of the substrate and without need for any teaching procedures.

---

# Sensor Installation Recommendations

URL: https://r2r.tech/documentation/manuals/sensor-installation-recommendations.md

One of the key steps involved in a web guiding system installation is the sensor installation. This document outlines a few key recommendations with regard to position and orientation of the sensor for different web position sensing applications.



ARIS WPS sensors are camera like sensors that work on the principle of light scattering. Hence the sensor performance is improved with proper installation that can increase light scattering while providing a good image.



## Sensor Working Distance and Background for Edge Sensing Application



The sensor for edge sensing is mounted in a free span between two rollers. The distance of the sensor from the web directly affects the amount of light scattered back from the web. Closer the web is to the sensor, more light will be back scattered from the web. The ideal recommendation for the distance between the sensor and the web is 5 mm to 15 mm. Note that the sensor would still provide measurement even if the web is farther than 15 mm, especially with webs (paper and nonwovens) that can scatter a lot of light back. Since the sensor is similar to a camera, objects behind the web in the field of view of the sensor may be picked up by the sensor. It is recommended that no object (or any other web path) be at a distance of 150 mm from the sensor to increase the performance of the sensor. These recommendations are illustrated as shown below.

 ![Typical Sensor Installation - Working Distance](https://r2r.tech/sites/default/files/inline-images/WPS-48-Sensor-Typical-Installation.png)

## Sensor Orientation to Maximize Scattering for Edge Sensing Application



Some webs reflect more light than the amount they scatter. For example, metallic, shiny and clear webs can reflect most of the incident light away from the sensor and scatter only a tiny fraction of the light. Since for reflective webs, the angle of incident of light is the same as the angle of reflection, proper angular orientation of the sensor with respect to the web would significantly improve the amount of light coupled back into the sensor. Since the LED light source inside the sensor is at an angle, the sensor can be tilted as shown below to improve its performance. The orientation of the tilt depends on how the sensor is mounted. Hence both the possible scenarios are illustrated in the sketch below.

 ![Sensor Installation to Improve Scattering](https://r2r.tech/sites/default/files/inline-images/WPS-48-Sensor-Typical-Installation-Clear-Web.png)

## Sensor Position and Orientation to Maximize Scattering for Contrast Sensing Application



For contrast sensing applications the working distance is critical since the sensor needs to pick up even the slightest difference in contrast in the web. It is also important to prevent any plane change, since such a change could be perceived as a contrast change by the sensor. Hence for contrast sensing application the web must be supported by a backup roller and the sensor is installed such that the distance from the sensor to the web is about 5 mm. Similar to the edge sensing application, the orientation of the sensor would improve the sensor performance. The recommendation for the contrast sensing application is illustrated below.

 ![Sensor Installation to Improve Scattering - Contrast Guiding](https://r2r.tech/sites/default/files/inline-images/Sensor-Installation-for-Contrast-Sensing.png)

---

# Sensor Installation Recommendations: Inspection Applications

URL: https://r2r.tech/documentation/manuals/sensor-installation-recommendations-inspection-applications.md

One of the key steps involved in a web inspection application is proper sensor installation. This document outlines a few key recommendations with regard to position and orientation of the sensor for web width and coating width inspection applications.

Roll-2-Roll® Sensors are camera based systems that work on the principle of light scattering. Hence the sensor performance is improved with proper installation that can increase light scattering while providing a good image.

## Sensor Working Distance and Background

Typically the sensor for web inspection is mounted in a free span between two rollers. The distance of the sensor from the web directly affects the amount of light scattered back from the web. Closer the web is to the sensor, more light will be scattered back from the web. The ideal recommendation for the distance between the sensor and the web is 5 mm to 20 mm depending on the sensor. Note that the sensor would still provide measurement even if the web is farther than the recommended distance for certain applications, however for inspection applications, the recommended distance is between 10 mm and 20 mm.

Since the sensor is similar to a camera, objects behind the web in the field of view of the sensor may be picked up by the sensor. It is recommended that no object (or any other web path) be at a distance of 150 mm from the sensor to increase the performance of the sensor. These recommendations are illustrated as shown below.

![Sensor Installation for Web Edge Position Detection, Web Guiding, Web Width Measurement and Web Inspection](https://r2r.tech/sites/default/files/inline-images/Edge-Detection-and-Guiding-Sensor-Typical-Installation-WPS-ODC.png)

For web inspection applications it is important to stabilize the web and remove any out-of-plane vibrations (variation in distance A as the web is transported). The out of plane vibrations can cause the web to be closer and farther away from the sensor creating varying amounts of back scatter. This affects the quality of the image captured and also creates artificial contrast variations that change as the web moves closer and farther away from the sensor. One of the simplest ways to stabilize the web is to install the sensor between two fixed idle rollers as shown here.

![Web inspection application ODC and WPS sensor Installation Recommendations](https://r2r.tech/sites/default/files/inline-images/Web-Inspection-Application-Installation-Recommendation.png)

The sensor may be installed on either side of the web. The choice depends on the ease of web threading as well as the available free space behind the web in the sensor’s field of view.

Additionally, installing the sensor closer to one of the rollers will also help with reducing the out of plane motion. Ensure that if and when the sensor is installed close to an idle roller, the background free space condition is met.

In the event of tight installation, a black matte artificial background can be used to overcome the requirement for the clear space behind the sensor. The black matte background will absorb the light from the sensor and prevent it from reflecting back into the sensor. It is important that the material is matte and black in color to ensure 100% absorption of the light from the sensor.

It is also important to ensure that the entire face of the sensor is at a constant distance from the web along the entire length of the sensor. This is necessary to have an uniform image intensity along the length of the entire sensor range.

![Sensor Installation to ensure web is at the same distance from the Roll-2-Roll Sensor.](https://r2r.tech/sites/default/files/inline-images/Sensor%20Parallel.png)

### Sensor Orientation to Maximize or Minimize Scattering for Inspection Applications

Some webs reflect more light than the amount they scatter. For example, metallic, shiny/glossy and clear webs can reflect most of the incident light away from the sensor and scatter only a tiny fraction of the light. Since for reflective webs, the angle of incident of light is the same as the angle of reflection, proper angular orientation of the sensor with respect to the web would significantly improve the amount of light coupled back into the sensor. Since the LED light source inside the sensor is at an angle, the sensor can be tilted as shown below to increase scattering.

#### Sensor Orientation to Maximize Scattering for WPS 112, 221, 440, ODC 96, 192, 288, 384, 480, 768

To maximize the scattering they need to be installed so that the LEDs inside are normal to the web. This can be achieved by installing the sensors as shown below. Note that the clockwise rotation is viewed from the end where the sensor connector is visible.

![Web inspeaction application sensor installation recommendation to increase scattering with Roll-2-Roll® Sensor](https://r2r.tech/sites/default/files/inline-images/Web-Inspection-Application-Installation-Recommendation-Increase-Scattering.png)

#### Sensor Orientation to Minimize Scattering for WPS 112, 221, 440, ODC 96, 192, 288, 384, 480, 768

The rotation of the sensor in the counterclockwise direction will result in reduction of scattering. This may be needed for certain applications to increase the contrast between two different surfaces. Especially in Lithium-Ion battery inspection applications it may be necessary to reduce the scattering to increase the contrast difference between the coated and uncoated web. This can be achieved by the orientation shown below.

![Web inspeaction application sensor installation recommendation to decrease scattering with Roll-2-Roll® Sensor](https://r2r.tech/sites/default/files/inline-images/Web-Inspection-Application-Installation-Recommendation-Decrease-Scattering.png)

---

# Servo Center Sensor - 2D Drawing

URL: https://r2r.tech/documentation/2d-drawings/servo-center-sensor-2d-drawing.md

Servo Center Sensor - 2D Drawing

---

# Servo Center Servo Installation

URL: https://r2r.tech/documentation/manuals/servo-center-servo-installation.md

## Working Principle



The servo centering is a term used to indicate the middle or center position of a web guide mechanism. For an intermediate web guide this would be the position where the web guide mechanism would be aligned with the rest of the machine so that idle roller(s) on the web guide would be parallel to the other fixed idle rollers on the machine. With terminal guides this would usually correspond to the middle of the stroke of the unwind/rewind carriage.



Roll-2-Roll Technologies typically use a M12 24 VDC NPN inductive proximity sensor with a suitable target to detect the servo center position. The servo center position can be detected on the web guide structure, or on the actuator directly. It has to be noted that depending on the web guide structure and its installation, the middle of the actuator stroke might not always match with the center position of the web guide structure. However, the servo center position is the center position of the web guide structure and not the center position of the actuator.



The servo center sensor is installed such that it detects a target for one half stroke of the actuator and does not detect the other half of the stroke of the actuator. The transition zone will be the servo center location for the web guide mechanism. The figure below shows the working principle of the servo center sensor at different positions of the target.

 ![Servo Center Operation Normal Polarity](https://r2r.tech/sites/default/files/inline-images/Servo-Center-Operation.png)

When the servo center button is pressed on the web guide controller, the initial state of the sensor is recorded before moving the actuator in a direction such that the transition or home position is reached. The direction in which the actuator/target/lead screw moves depends on the polarity setting of the servo center functionality. If the target position is reversed then the different scenarios for the servo centering operation would also have the opposite polarity as shown in the following illustration.



When the servo centering operation is started, the actuator would move in a direction to see the transition point. Since a proximity switch the change of state could have a hysteresis depending on the direction of motion of the actuator. To ensure that the transition is always at the same location, the servo center operation could continue to move the actuator past the transition point and then bring it back. This functionality is implemented in some versions of the web guide controller.



Note that if the servo center polarity is set incorrectly, the actuator would move away from the center position. Additionally, if the distance between the target and the proximity sensor goes beyond the working distance of the proximity sensor the functionality of the servo center operation would be affected. Standard working distance for inductive proximity sensors are around 1.5 mm to 3 mm.

 ![Servo center operation reversed polarity](https://r2r.tech/sites/default/files/inline-images/Servo-Center-Operation-Oppositve-Polarity.png)

## Pre-installed Servo Center Sensor on Web Guide



For most web guides made by Roll-2-Roll Technologies, the servo center sensor would be pre-installed at the appropriate location with an appropriate target. For some models of the web guide mechanism, the proximity sensor might look at the lead screw on the back of the actuator. This would be the standard polarity for the servo center operation as shown in the first illustration. For some other models, the servo center sensor would look at the linear slide carriage connected to the rod end of the actuator. This would correspond to the reversed polarity of the servo center operation as shown in the second illustration.



No adjustment is needed when the servo center is pre-installed on the web guide mechanism.



## Servo Center Sensor on Upgrade and Retrofit Actuator



The Roll-2-Roll actuators that are used in upgrade and retrofit applications may have the servo center sensor installed on the actuator with an appropriate mounting bracket. The proximity sensor would be installed to look at a translating linear support shaft of the actuator. If the sensor is not installed on the actuator, then the user can install the sensor looking at the exposed lead screw of the actuator (as shown below) or with a dedicated target.

 ![Retrofit actuator servo center installation](https://r2r.tech/sites/default/files/inline-images/Retrofit-Actuator-Servo-Center-Installation.png)

A provision to linearly move the proximity sensor parallel to the stroke of the actuator allows the user to set the transition point anywhere on the stroke of the actuator. This enables the proper location of the transition point based on the center position of the web guide mechanism, rather than the center of the actuator stroke.

 ![Retrofit actuator TF servo center installation](https://r2r.tech/sites/default/files/inline-images/Retrofit-Actuator-TG-Servo-Center-Installation.png)

Most often the available mechanical stroke length on the actuator may be more than the stroke available on the web guide mechanism. Once the servo center sensor is installed at the middle of stroke of the web guide mechanism, the electronic stroke of the actuator can be adjusted so that the actuator never hits the mechanical limits of the web guide mechanism. This increases the life of the actuator and avoids any premature actuator failure.



## Servo Center Sensor on Unwind/Rewind Carriage



Depending on the actuator used, the servo center sensor can be installed on the actuator or installed to look at a target that moves with the unwind/rewind carriage. If the lead screw on the actuator is exposed then the servo center sensor can be installed to look at the lead screw.



## Importance of Servo Center



Servo centering a web guide is an important step for good web guiding performance. This is because when the web guide is servo centered before a production run, the web guide would have equal stroke on either direction to correct for any errors. If this step is skipped, it is possible that the web guide mechanism might have a bias towards one side before the start of a new run. This bias could limit the correction in that direction if the actuator stroke limit is reached in that direction during the run.



Roll-2-Roll web guide controllers use the servo center position as the zero position of the actuator which is used for the electronic stroke limit. The actuator would only move one half of the electronic stroke limit on either side of the zero position. If this sensor does not work or if the zero position is incorrect, then the web guide performance may be limited because of the electronic stroke limit.

---

# Standard Operating Procedure (SOP): Center Guiding Application (v2.x)

URL: https://r2r.tech/documentation/manuals/standard-operating-procedure-sop-center-guiding-application-v2x.md

This document provide the standard operating procedure for the center guiding application. This can be printed, laminated and displayed next to the web guide for easy training to new operators. 

---

# Standard Operating Procedure (SOP): Edge Guiding Application (v2.x)

URL: https://r2r.tech/documentation/manuals/standard-operating-procedure-sop-edge-guiding-application-v2x.md

This document provide the standard operating procedure for the simple edge guiding application. This can be printed, laminated and displayed next to the web guide for easy training to new operators. 

---

# Standard Operating Procedure (SOP): Edge Guiding Application (v3.x)

URL: https://r2r.tech/documentation/manuals/standard-operating-procedure-sop-edge-guiding-application-v3x.md

This document provide the standard operating procedure for the simple edge guiding application. This can be printed, laminated and displayed next to the web guide for easy training to new operators. 

---

# Standard Operating Procedure (SOP): Line Guiding Application

URL: https://r2r.tech/documentation/manuals/standard-operating-procedure-sop-line-guiding-application.md

This document provide the standard operating procedure for the simple line guiding application. This can be printed, laminated and displayed next to the web guide for easy training to new operators.

---

# Standard Operating Procedure - Center Guiding Application (v3.x)

URL: https://r2r.tech/documentation/manuals/standard-operating-procedure-center-guiding-application-v3x.md

This document provide the standard operating procedure for the simple center guiding application. This can be printed, laminated and displayed next to the web guide for easy training to new operators. 

---

# Unwind/Rewind Guides Brochure

URL: https://r2r.tech/documentation/brochures/unwindrewind-guides-brochure.md

Unwind/Rewind Guides Brochure

---

# Unwind/Rewind Installation Checklist

URL: https://r2r.tech/documentation/manuals/unwindrewind-installation-checklist.md

Unwind/Rewind Installation Checklist

---

# Upgrade Kit Installation Checklist

URL: https://r2r.tech/documentation/manuals/upgrade-kit-installation-checklist.md

Roll-2-Roll® upgrade kit installation checklist.

---

# Web Edge Sensor Comparison

URL: https://r2r.tech/documentation/brochures/web-edge-sensor-comparison.md

Web Edge Sensor Comparison

---

# Web Guide Installation Checklist

URL: https://r2r.tech/documentation/manuals/web-guide-installation-checklist.md

Web Guide Installation Checklist

---

# Web Guide Upgrade or Retrofit Kit

URL: https://r2r.tech/documentation/manuals/web-guide-upgrade-or-retrofit-kit.md

This document provides user and operation information for the web guide retrofit kit. 

---

# Web Guide: Disturbance Rejection Performance

URL: https://r2r.tech/documentation/white-papers/web-guide-disturbance-rejection-performance.md

## Introduction



Regulating the lateral position of the web material in a roll-to-roll machine is critical for a wide variety of converting applications. Variations in lateral position can result in substandard finished product. In extreme cases the web material might break because of lateral position variation leading to machine downtime.  Roller misalignment, web splices, web thickness variations, roller thickness variations, poor quality input roll, web camber are the primary causes of lateral variations. Even with a perfectly aligned machine with well machined rollers, poor quality raw material (cambered web or webs with thickness variations or with wound roll edge variations) will result in lateral variations. Hence it is necessary to control these variations actively using a web guide system.



Active control of the material's lateral position in manufacturing machines is carried out using intermediate guide or a terminal guide. Intermediate guides, as the name suggests, are used in the middle of the roll-to-roll machine at a location where accurate lateral position control is desired. While terminal guides are used to regulate the position of the raw material fed into the machine or the finished product produced by the machine.



## What is a displacement guide or an offset-pivot web guide?



Several types of intermediate guides are used to control the lateral position of the web materials. These include: displacement guide or offset-pivot guide, steering guide, center pivoted guide and end pivoted guide. The latter two guides are rarely used in contemporary machines.



The most common type of a lateral guide is a displacement guide (see Fig. 1). Displacement guides have a pivoting platform with two rollers. The two rollers move in tandem and are always parallel to each other as the web guide platform pivots. Displacement guides are simpler to install and use. If installed properly, the web guide can truly displace the web without introducing bending stresses in the web. This whitepaper deals with the performance of a displacement guide with common disturbances seen in converting lines.

 ![ARIS Web Compact Guiding System used in this whitepaper is a displacement web guide](https://r2r.tech/sites/default/files/inline-images/aris-web-guiding-system-old.png)

## How to quantify web guiding performance?



The performance of a web guiding system is a function of several parameters such as the precision and accuracy of the edge sensor, the precision and accuracy of the guide mechanism, and the speed or the dynamics response of the guide mechanism. The dynamic behavior of the web on the rollers is also an factor that affects the web guide's performance.



Web guide manufacturers typically provide specification of the guiding system without much data about performance quantification. This is mainly because of the fact that the guiding performance is subjective and depends on various process parameters such as web speed, tension, traction, sensor resolution and accuracy, dynamic response of the guide mechanism, etc. Moreover, most of the currently available sensors provide an indirect/inferred measurement which is dependent on the physical properties of the material; quantification based on an inferred measurement is also subjective. However, the web guide used in this whitepaper is equipped with a patented material agnostic fiber optic web edge sensor which provides true, absolute measurement of the web position. Hence a true quantification of the web guiding performance are made easily. The detailed specification of the parameters of the web guide used in these experiments are shown in the table below.



| Specification | Dimension/Value | Units |
| ------------- | --------------- | ----- |
| Roller Width | 254 | mm |
| Maximum Correction | 52.75 | mm |
| Displacement Resolution | 0.000275 | mm |
| Maximum Linear Speed | 130.00 | mm/sec |
| Maximum Linear Force | 250 | N |
| Sensor Resolution | 0.0635 | mm |
| Sensing Window | 16 | mm |
| Sensing Frequency | 200 | Hz |
| Control Frequency | 50 | Hz |



## Experimental roll-to-roll machine



In order to quantify the web guiding performance, we test the web guides in an in-house closed-loop roll-to-roll experimental platform (see Fig. 2). The length of web material threaded in the machine is about 20 meters and the web is transported up to 10 meters/sec. The web tension in the machine is maintained using a pneumatic dancer system. Webs with 100 mm and up to 450 mm in width are transported in the machine. The machine is also equipped with two web guides to regulate web position. Two spans with a total length of 1200 mm separate the two web guides. For experimental purposes the upstream guide is used to create disturbances while the downstream guide is used to correct for the disturbances.

 ![The Experimental roll-to-roll machine used for testing the web guides.](https://r2r.tech/sites/default/files/inline-images/Test-Machine_1.png)


 Two additional sensors, with a sensing window of 48 mm (see Fig. 3), are used to measure the lateral position before and after the downstream web guide. These sensors provide a clear quantification of the magnitude of lateral disturbance entering the web guide and the corrective response of the web guide.

 ![Sensors measuring web position upstream and downstream of the web guide.](https://r2r.tech/sites/default/files/inline-images/Sensors-Setup_0.png)

## Sinusoidal Disturbance Rejection Performance of the Web Guide



Sinusoidal disturbances are common lateral errors seen in industrial converting machines. Hence the performance of the web guiding system is evaluated for sinusoidal disturbances. In the experiments reported in this white paper, sinusoidal lateral disturbances with a magnitude of 8 mm and frequencies of 0.25 Hz, 0.5 Hz, 1 Hz, 2 Hz and 5 Hz were introduced with the upstream web guide while the downstream web guide is used to correct for the disturbances. Kraft paper with a width of 152 mm was transported in the machine with varying speeds up to about 5 m/sec; tension was maintained in the machine using a passive dancer.



A summary of the time domain results are shown in Fig. 4. All the plots show the disturbance entering the guide roller (measured using the upstream web edge sensor) and the guiding performance of the web guide (measured in the downstream span using a sensor). A FFT of the lateral disturbance and the web guiding performance is shown in Fig. 5 to further summarize the results.

 ![Sinusoidal disturbance rejection performance of ARIS Web Guiding System. The incoming disturbance is shown in red and the response after the web guide correction is shown in blue. Web guide’s performance at different frequencies are shown in the three plots.](https://r2r.tech/sites/default/files/inline-images/sinusoidal-disturbance-rejection-experimental-results_0.png)![The frequency domain information of the data shown in Fig. 4 is shown. The web guide is capable of rejecting disturbances up to a frequency of 4 Hz as seen from the FFT plot above. Significant reduction is seen at lower frequencies. ](https://r2r.tech/sites/default/files/inline-images/fft-sinusoidal-disturbance-rejection-experimental-results_0.png)

## Step Disturbance Rejection Performance of the Web Guide



Response to step disturbance is a key performance metric that quantifies the response time of the web guide and the magnitude of attenuation. These types of disturbances are common with web splices or sudden web position changes. Moreover, the step response can theoretically excite all disturbance frequencies. Hence the step response is a good performance metric for performance quantification. Experiments were conducted to evaluate the guide performance of the web guide for these types of disturbances and a summary of results are shown in Fig. 6. The disturbance entering the guide roller is captured by the upstream sensor while the actual lateral position downstream of the guide roller is measured using the downstream sensor.

 ![Step disturbance rejection performance of the web guiding system at different web speeds. The disturbance observed at the upstream sensor as well as the response after the web guide is shown in the figure above. ](https://r2r.tech/sites/default/files/inline-images/step-disturbance-rejection-experimental-results_0.png)

## Summary and Conclusions



From the experimental results it is evident that the web guide provides accurate guiding performance in the presence of both sinusoidal and step disturbances. Significant reduction in sinusoidal disturbances were observed with low frequency disturbances and rapid response to step disturbances were also observed. Further increase in performance in the guiding performance can be obtained with a high dynamics response actuator. This is discussed in another whitepaper.

---

# Web Guides: Dynamic Performance with High Speed Actuator

URL: https://r2r.tech/documentation/white-papers/web-guides-dynamic-performance-high-speed-actuator.md

## Introduction



In a [previous whitepaper](https://r2r.tech/documentation/web-guide-disturbance-rejection-performance) the disturbance rejection performance of Roll-2-Roll Technologies' web guides was reported for sinusoidal and step disturbances. This whitepaper reports the performance of the same web guide with a high speed actuator along with an improved sensing algorithm. A new high performance actuator with a maximum linear speed of 172.35 mm/sec and maximum displacement of 45 mm is used with a high performance chopper drive with 256 microstep resolution. Modifications to the web guide mechanism to reduce transmission compliance was also made to improve the performance. The improved high performance web guiding system is intended to be used in demanding high speed, low tension converting applications such as diaper and adult incontinence manufacturing. The detailed specification of the web guide is shown in Table 1 below.



| Specification | Dimension/Value | Units |
| ------------- | --------------- | ----- |
| Roller Width | 254 | mm |
| Maximum Correction | 45.25 | mm |
| Displacement Resolution | 0.000248 | mm |
| Maximum Linear Speed | 172.35 | mm/sec |
| Maximum Linear Force | 133 | N |
| Sensor Resolution | 0.0635 | mm |
| Sensing Window | 16 | mm |
| Sensing Frequency | 100 | Hz |
| Control Frequency | 100 | Hz |



## Sensing Algorithm Improvements



The previous sensing algorithm used was a simple Gaussian digital signal processing algorithm to detect the web position. Even though the algorithm was robust it was affected by optical design issues that reduced the sensor resolution to be about 0.3175 mm instead of 0.0635 mm. An advanced digital signal processing algorithm that automatically adjusts to the web material has since been implemented to improve the sensor resolution. Essentially the new algorithm self calibrates or adapts every sampling time to provide the most accurate measurement. The results from experiments quantify the sensor resolution to be 0.0635 mm and linearity error to be less than ± 1% is reported in the white paper titled “[Material Agnostic Fiber Optic Web Edge Sensor.](https://r2r.tech/documentation/material-agnostic-fiber-optic-web-edge-sensor)”



## Controller Optimizations



Several controller optimization algorithms were tested and implemented in the new web guiding system. Optimizations to acceleration profile, velocity profile and position profile for the web guide were carried out to obtain the best performance for the web guiding system. Controller can now use either position or velocity based control system, with in-built current control in the high performance stepper motor driver.

 ![ARIS Web Compact Guiding System](https://r2r.tech/sites/default/files/inline-images/aris-web-guiding-system_1.png)

## Web Guide's Mechanical Design Improvements



Mechanical design improvements to reduce the compliance in the transmission, reduce inertia of the guide mechanism, reduce friction in the guide rails and to install the sensor as close to the guide roller as possible were made.



## Experimental Roll-to-Roll Machine



In order to quantify the guiding performance we test the web guides in an in-house closed-loop roll to roll experimental platform (see Fig. 2). The length of web material threaded in the machine is about 20 meters and the web can be transported at a speed of up to 10 meters/sec. The web tension in the machine is maintained using a pneumatic dancer system. Webs with 100 mm and up to 450 mm in width can be transported in the machine which is equipped with two web guides. Two spans with a total length of 1200 mm separate the two web guides. For experimental purposes the upstream guide is used to create disturbances while the downstream guide is used to correct for the disturbances.

 ![The Experimental roll-to-roll machine used for testing the web guides.](https://r2r.tech/sites/default/files/inline-images/Test-Machine_3.png)

Two additional sensors, with a sensing window of 16 mm (see Fig. 3), are used to measure the lateral position before and after the downstream web guide. These sensors provide a clear quantification of the magnitude of lateral disturbance entering the web guide and the corrective response of the web guide.

 ![Sensors measuring web position upstream and downstream of the web guide.](https://r2r.tech/sites/default/files/inline-images/Two-Sensor-Setup_0.png)

## Sinusoidal Disturbance Rejection



Sinusoidal disturbances are common lateral errors seen in industrial converting machines. Hence the performance of the web guiding system is evaluated for sinusoidal disturbances. In the experiments reported in this white paper, sinusoidal lateral disturbances with a magnitude of 8 mm and frequencies of 0.25 Hz, 0.5 Hz, 1 Hz, 2 Hz and 4 Hz were introduced with the upstream guide while the downstream guide is used to correct for the disturbances. A nonwoven web of width 130 mm was transported at a speed of 6.6 meters/sec (1300 feet-per-minute). The web tension in the machine was maintained using a pneumatic dancer system.



A summary of the time domain results are shown in Fig. 4. The plots show the disturbance entering the guide roller (measured using the upstream sensor) and the performance of the web guiding system (measured at the downstream span using a sensor). A FFT of the lateral disturbance and the guiding performance is shown in Fig. 5 with the Table 2 that further summarizes the results.

 ![Sinusoidal disturbance rejection performance of ARIS Web Guiding System. The incoming disturbance is shown in red and the response after the web guide correction is shown in blue. Web guide’s performance at different frequencies are shown in the three plots.](https://r2r.tech/sites/default/files/inline-images/sinusoidal-disturbance-rejection-experimental-results-high-speed-actuator_0.png)![The frequency domain information of the data shown in Fig. 4 is shown. The web guide with high speed actuator is capable of rejecting high frequency disturbances over 4 Hz as seen from the FFT plot above. ](https://r2r.tech/sites/default/files/inline-images/fft-sinusoidal-disturbance-rejection-experimental-results-high-speed-actuator_0.png)

| Disturbance Frequency (Hz) | Upstream Sensor Measurement (mm) | Downstream Sensor Measurement (mm) | Attenuation % |
| -------------------------- | -------------------------------- | ---------------------------------- | ------------- |
| 0.25 | 7.68 | 0.34 | 95.57 |
| 0.5 | 7.27 | 0.49 | 93.26 |
| 1 | 5.09 | 0.72 | 85.85 |
| 2 | 5.75 | 1.27 | 77.91 |
| 4 | 1.39 | 0.43 | 69.06 |



## Summary and Conclusions



Significant improvement in performance was achieved with the improvements due to the new actuator, modifications to the sensor algorithm, optimization of the controller parameters, and improvements to the guide mechanism. Especially at frequencies between 1 to 4 Hz a significant improvement was observed. The previous control system was unable to attenuate the disturbances at these frequencies. However it is noted that these performance improvements will be added to the standard [ARIS Web Guiding System](http://r2r.tech/product-groups/web-guides) only when such performance is absolutely needed.



In order to reject the high frequency disturbance the acceleration and velocity profiles of the controller were optimized to be at their maximum limits. High acceleration profiles require low inertia of the guiding system which implies the tension on the web guide should also be low. Hence care must to taken to ensure that the guide mechanism is not overly loaded when these high performance controller parameters are used.



The most significant loading of the motor occurs during direction change. The motor has to overcome the inertia of the guide mechanism to the stop the guide and to start accelerating in the other direction. And as the frequency of the disturbance increases the loading duty cycle also increase. A high duty cycle loading with a DC or a Brushless DC motor may result in actuator failure. The DC motors draw current based on the load on the motor. As the load increases or the duty cycle of the load increase, higher current is draw which may result in overheating and actuator damage. Stepper motors on the other hand draw a constant current and will stall if the load is excessive. This prevents the motor from overheating and prevents actuator failure with high frequency disturbance.



The high performance stepper motor driver in ARIS Web Guiding System is optimized to prevent stalls and for load-adaptive current scaling to reduce the energy consumption. This prevents the overheating issue while providing maximum efficiency. Higher acceleration profiles can be achieved by increasing the coil windings, using a bulkier motor with a high throughput current driver. All of these will increase the overall size of the actuator and the power consumption of the [ARIS Web Guiding System](http://r2r.tech/product-groups/web-guides).



An alternative to using a high performance actuator is the use of a standard web guide with a properly designed web path. The inherent filtering (or absorbing) nature of the web can be exploited to reduce the disturbance propagation. The simplest option would be to have long web spans which can absorb high frequency lateral disturbances. Such a design would be a reliable cost effective solution compared to using a bulkier high speed actuator which may be prone to actuator failure.

---

# Web Guides: Frequency response of the guide mechanism

URL: https://r2r.tech/documentation/white-papers/web-guides-frequency-response-guide-mechanism.md

## Introduction



The performance of a web guiding system depends on the positional accuracy of the guide mechanism, the accuracy of the sensor, the precision of the sensor, the dynamic response of the sensor (speed of measurement) and the dynamic performance of the actuator positioning the guide mechanism. [The accuracy, precision and linearity of the sensor measurement](https://r2r.tech/articles/accuracy-precision-linearity-and-resolution-web-guiding-understanding-terminology) was discussed in a previous white paper along with the discussion of [sensing performance of the ARIS web position sensor](https://r2r.tech/documentation/material-agnostic-fiber-optic-web-edge-sensor) in another white paper. In this white paper we discuss the dynamic response capability of the web guide mechanism.



“Frequency response” or the “bandwidth” of the guide mechanism characterizes the dynamic response of the guide mechanism. In general the higher the bandwidth, the faster the guide mechanism can respond to disturbances. Intermediate guides such as a steering guide or a [displacement guide](https://r2r.tech/articles/web-guides-or-web-guiding-systems-overview) are typically powered by an electric motor through a coupling and actuation system. Other less common actuation systems in intermediate web guides include pneumatic and hydraulic cylinders.



The [overall frequency response of the web guide mechanism](https://www.youtube.com/watch?v=QQKfuqWKoAo) is a function of the power available to the motor, the capability of the motor, the capability of the actuator, losses in the coupling mechanism, the mechanical friction/transmission losses and the overall inertia of the guide mechanism. In order to maximize the bandwidth or frequency response of the guide mechanism the overall electro-mechanism system should include:



- high performance motor, motor driver and power supply
- actuator with low transmission losses and backlash
- low friction transmission system and mechanical assembly



## High Performance Guide Mechanism



The [compact web guiding system](https://r2r.tech/web-guides/aris-compact-web-guiding-system) is a type of displacement web guide equipped with a high performance linear hybrid stepper actuator. The linear hybrid stepper actuator is directly coupled to a low friction linear bearing system that supports the roller platform of the guide mechanism (see Fig. 1).

 ![Inside view of the guide mechanism](https://r2r.tech/sites/default/files/inline-images/Inside%20view%20of%20compact%20web%20guiding%20system.png)

The linear hybrid actuator has a resolution of 0.0508 mm/step or 0.000198 mm/microstep. Based on the transmission ratio of the guide mechanism, each step corresponds to 0.0704 mm. The linear hybrid actuator is powered by a high performance constant current chopper drive which can generate in excess of 500,000 microsteps per second. Hence the overall maximum speed of the guide mechanism is about 130 mm/sec or 5.12 in/sec. The detailed specification of the guide mechanism is shown in table 1 below.



| Specification | Dimension/Value | Units |
| ------------- | --------------- | ----- |
| Roller Width | 254 | mm |
| Maximum Correction | 52.75 | mm |
| Displacement Resolution | 0.000275 | mm |
| Maximum Linear Speed | 130.00 | mm/sec |
| Maximum Linear Force | 250 | N |
| Time period for maximum correction | 0.425 | sec |
| Control frequency | 200 | Hz |



## Frequency Response of the Guide Mechanism



One way to efficiently summarize the performance of the web guide mechanism is through its frequency response. The constant current chopper driver and the stepper motor are highly non-linear switching systems. Therefore a traditional frequency response based on a Bode diagram cannot be obtained. However, given all the parameters of the driver and the stepper motor, it is possible to analytically compute the maximum amplitude of travel for a sinusoidal reference input for a given frequency. Fig. 2 shows the theoretical frequency response for the high performance guide mechanism. The blue solid line shows the theoretical maximum possible correction for frequencies in the range of 1 to 10 Hz.

 ![Comparison of the actual and theoretical frequency response of the guide mechanism](https://r2r.tech/sites/default/files/inline-images/guide_mechanism_frequency_response_capability.png)

Set of experiments were performed at frequencies between 1 Hz and 10 Hz to compare the theoretical response with the actual response measured from the guide mechanism. The high performance stepper motor driver was used to command the motor to oscillate at a given frequency with the maximum amplitude. The actual movement of the guiding system were measured using a linear optical quadrature encoder with a resolution of 0.003175 mm/count. The encoder measurement was used to verify that the linear hybrid stepper actuator motor does not stall at high microstep pulse rates. The encoder measurement indeed verified the high precision performance of the system which closely matches the theoretical response without any stalling. Stalling is a common issue with low quality voltage based stepper drives. It is important to ensure that high performance constant current chopper driver is used to prevent stalling.



Fig. 3 shows the time domain data from the experiments. The ordinate shows the guide mechanism displacement in millimeters. The displacement is measured using the linear optical encoder. The abscissa is time in seconds. Note that at low frequencies the maximum travel is bounded by the stroke length of the linear hybrid actuator, while at higher frequencies it is limited by the maximum speed of the actuator. A video showing the frequency response of the guide is available here.

 ![Response of the guide mechanism with a frequency sweep](https://r2r.tech/sites/default/files/inline-images/guide_mechanism_frequency_sweep_profile.png)

## Conclusion



The performance data shows that as the frequency increases above 5 Hz the maximum possible correction drops below 10 mm. Additional performance increases are possible with custom actuators and motor drivers as discussed in another white paper. It has to be noted that guide mechanism inertia, the friction system and transmission compliance would become limiting factors for increasing bandwidth.

---

# Web Guides: How to Quantify the Dynamic Performance?

URL: https://r2r.tech/documentation/white-papers/web-guides-how-quantify-dynamic-performance.md

##  



> ## ARIS Web Guiding Systems has been rebranded as Roll-2-Roll® Web Guiding Systems



## How are web guides performance specified?



Web guide manufacturers typically provide the specification of web guiding systems without much data about performance quantification. Specifications such as maximum web correction, sensor resolution, and maximum correction speed of a web guide are provided instead of performance data such as web position sensor accuracy, web guiding accuracy, closed loop response speed and other performance metrics. Inaccuracies in the sensing principles in existing web edge sensors and control systems is one of the main reasons why web guide manufacturers avoid providing these performance values. This means conventional web edge sensors and control systems are not accurate.



Another reason is the web guides' performance is also subjective and depends on process conditions such as web speed, web tension, web stiffness, traction, etc. Most often the only subjective condition that can adversely affect the web guiding performance is the traction between the web and the roller.



## How to truly quantify or specify web guiding performance?



In this article, we provide a detailed performance quantification of the ARIS Web Guiding Systems with experimental results to back our numbers. The ARIS Web Guiding Systems performance was quantified in a previous article, to show the web guide’s ability to attenuate sinusoidal and step disturbances. Some additional improvements with a high-performance actuator were also published in another article. This article focuses on the dynamic response characteristics of the ARIS Web Guiding Systems using step response experiments which provide a clear insight into the closed-loop performance characteristics of the web guides. Detailed specifications of the web guiding system used in the experiment are shown in Table 1.



| Specification | Dimension/Value | Units |
| ------------- | --------------- | ----- |
| Roller Width | 254 | mm |
| Maximum Correction | 45.25 | mm |
| Displacement Resolution | 0.000248 | mm |
| Maximum Linear Speed | 172.35 | mm/sec |
| Maximum Linear Force | 133 | N |
| Sensor Resolution | 0.0635 | mm |
| Sensing Window | 16 | mm |
| Sensing Frequency | 100 | Hz |
| Control Frequency | 100 | Hz |



## Web Guide's Dynamic Performance



To provide a better insight into the performance of the ARIS web guides, step response characteristics are shown in this article. Both open loop and closed-loop experiments are carried out to show the dynamic response characteristics of the web guiding systems. Dynamics or transient response to a 10.8 mm guiding point change or step reference change is used to highlight the closed-loop web guiding performance.



The step response of a system provides useful information about the transient response such as rise time, overshoot, settling time, steady-state error and maximum correction rate. Theoretically, a step response excites all frequencies and can be a predictor of other system performances such as disturbance rejection and closed-loop system bandwidth. The open loop step response experiments are also shown to provide an insight into the inherent lateral web dynamics.



## Experimental Roll-to-Roll Platform



In order to quantify the web guiding performance, we conduct tests on an in-house roll-to-roll experimental platform (see Figure 1).

 ![Experimental roll-to-roll machine](https://r2r.tech/sites/default/files/inline-images/Test-Machine.png)

The length of web material threaded in the machine is about 20 meters and the web can be transported at a speed of up to 10 meters/sec. The web tension in the machine is maintained using a pneumatic dancer system. Webs with 100 mm and up to 450 mm in width can be transported in the machine which is equipped with two web guides. Two spans with a total length of 1200 mm separate the two web guides. For experimental purposes, the upstream guide is used to maintain the position of the incoming web while the downstream guide is used for both open loop and closed-loop step response tests. One additional sensor, with a sensing window of 16 mm, is used to measure the lateral position of the downstream web guide (see Figure 2). This measurement is used to understand and visualize the lateral web dynamics of a free span downstream of the web guide.

 ![Picture of the sensor measuring web position downstream of the web guide](https://r2r.tech/sites/default/files/inline-images/Downstream-Sensor-Setup.png)

## Web Guide's Dynamic Performance: Open Loop Step Response



The open loop step response shows how the web position changes with respect to the web guide displacement. In this experiment the web guide was displaced 8 mm (step displacement) at the maximum speed of 172 mm/sec. Figure 3 and Figure 4 show the position of the web guide displacement (solid red line) and the corresponding web position displacement (dotted blue line) for the two speeds.

 ![Open loop response of ARIS Web Guides](https://r2r.tech/sites/default/files/inline-images/Open-loop_0.png)![A close-up view of the open loop step response of ARIS Web Guiding System](https://r2r.tech/sites/default/files/inline-images/Open-loop-Zoom-In.png)

It is evident that the lateral web dynamics with a displacement guide (ARIS Web Guiding System uses a displacement or an offset-pivot guiding mechanism) is a first order response with dc-gain equal to one. It is also evident (see Figure 4) that the web response speed is directly proportional to the web transport speed. In particular as the transport speed of the web increases the lateral dynamic response of the web accelerates. At 1.65 m/s it takes about 2 s to reach the steady state value while at 6.6 m/s it only takes about 0.4 s.



The maximum web speed was measured to be 139.7 mm/sec for both web transport speeds. However, the average lateral web speed during the transient slowed considerably with the decrease in web transport speed. This clearly shows that the open loop system bandwidth (the location of the poles) depends on the speed of transport. The results of the experiments are directly in line with the model predictions provided in our previous article on lateral web dynamics.



The change in dynamic response or the change in bandwidth of the underlying system may pose difficulties to static or fixed gain feedback controllers. Typically the feedback controllers increase or decrease the bandwidth of the system (move the poles away or closer to the imaginary axis) by increasing or decreasing the overall gain of the system. Since the bandwidth is low for slow web transport speeds it is necessary to increase the controller gains to attain higher closed-loop bandwidth or response.



If the feedback controller is tuned for the slow transport speed (higher controller gains), it will overreact if the transport speed increases (the overall gain of the system becomes too high). On the other hand, when the feedback controller is tuned for fast transport speed (lower controller gains), it will under perform if the transport speed decreases (the overall gain of the system becomes too low). Hence in order to obtain the optimal performance, it is necessary to re-tune the system every time speed changes are experienced. Or a feedback controller that can automatically adapt to the speed changes is necessary. The ARIS web guiding system overcomes this problem with its sophisticated control system and keeps a consistent response over varying transport speeds.



## Web Guide's Dynamic Response: Closed-loop Step Response 



The step response is defined as the response of a dynamic system to an instantaneous change in reference input. To highlight the capabilities of the ARIS web guides, we chose a step change of approximately 2/3 the width of the sensing window of the sensor (10.795 mm). Figure 5 and Figure 6 show the closed-loop step response characteristics of the ARIS web guiding system for 1.65 m/s and 6.6 m/s.

 ![Closed loop step response of ARIS Web Guiding System](https://r2r.tech/sites/default/files/inline-images/Closed-loop.png)![A close-up view of the closed loop step response of ARIS Web Guiding System](https://r2r.tech/sites/default/files/inline-images/Closed-loop-Zoom-In.png)

The plots show the reference input (dotted green line), the closed-loop response of the web guiding system (shown by solid red line), and the lateral position of the web downstream of the exit span of the web guide (dotted blue line). As seen from the plots, the open loop response of the system is significantly improved with the feedback control used in ARIS web guiding system. The maximum web correction speed increased from 139.7 mm/s (in open loop) to 152.4 mm/s and 171.45 mm/s for the two web transport speeds. The rise time of the system (the time taken to go from 10% to 90% of the reference) also decreased significantly from 240 milliseconds (open loop) to 80 milliseconds for 1.65 m/s web transport speed, and from 180 milliseconds (open loop) to 60 milliseconds for 6.6 m/s web transport speed. An overall 67.67% improvement in speed is achieved with the closed-loop system.



Note, the step response remains substantially unchanged demonstrating the ability of ARIS web guiding system to overcome the challenges due to the changing underlying dynamic system. Another key characteristic of the system response seen in the plots is the overshoot characteristics. Even when the web is displaced with the maximum correction rate, the overshoot in the system is not significant. A clean first-order like the response is observed for the closed-loop response with a settling time of fewer than 100 milliseconds which is more than sufficient for most converting applications. The step response also provides an insight into the bandwidth of the closed-loop system. Using the general relationship between bandwidth (BW) and rise time,

  ![Bandwidth equation](https://r2r.tech/sites/default/files/inline-images/Bandwidth-equation.png)

we see that the bandwidth is about 4.375 Hz for 1.65 m/s and 5.83 Hz for 6.6 m/s. Note that the theoretical bandwidth of the guide mechanism is 6.98 Hz and the lateral web dynamics, which is influenced by the web transport speed, decreases the bandwidth of the system. Essentially the web acts as a low pass filter and absorbs the high frequencies and reduces the overall speed of the closed-loop system. To clearly see the filtering effect of the web, the web edge position downstream of the guide exit span is measured and shown in the plots in Figure 5. From the plots, it is evident that as the speed decreases the rise time or the bandwidth of the lateral web dynamics is lowered. Even though the closed-loop response of the system at the guide exit span is fast, the lateral web dynamics further filters or slows the response in the downstream span. Hence it has to be noted that the web transport speed is going to limit the achievable response speed in the spans downstream of the web guide. No matter the speed of correction in the web guide exit span, the correction needs to go through the dynamics of the web in the subsequent spans which will slow down the response speed based on the web transport speed.



## Summary and Conclusions



Open loop and closed-loop step response of a dynamic system clearly demonstrate the dynamics response capabilities of the system. In this article, both open loop and closed-loop step response characteristics of the ARIS web guiding system were highlighted. The experimental data clearly showed the excellent performance characteristics of the web guide in terms of rise time, overshoot and settling time. Moreover, the data also showed how ARIS Web Guiding System is able to adapt to changing process condition (web transport speed) and maintaining the same level of performance. It has to be noted that the controller gains were never changed or tuned for any of the experiments.



The article also highlighted the effect of web speed on the lateral dynamics and how it affects the overall achievable performance for the web guiding system. Essentially the web acts as a low pass filter with the bandwidth of the filter being directly proportional to the speed of web transport. As the speed decreases the response of the closed-loop system also slows down. Even though the web guide is capable of improving the response in the web guide exit span, the effect will not be seen downstream unless the web transport speed is sufficiently high.

---

# Wide Web Guides Product and User Manual

URL: https://r2r.tech/documentation/manuals/wide-web-guides-product-and-user-manual.md

This product manual provides information about installation, use and maintenance of Wide Web Guides. The web guiding system is designed for use in indoor industrial and laboratory equipment that process materials in web form as they move through a converting or raw material manufacturing process.

---

# Wide Web Guides Product Brochure

URL: https://r2r.tech/documentation/brochures/wide-web-guides-product-brochure.md

The product brochure for the wide web guides.

---

# WPS 112 with Standard Mounting Brackets: 2D Drawing (pdf)

URL: https://r2r.tech/documentation/2d-drawings/wps-112-standard-mounting-brackets-2d-drawing-pdf.md

WPS 112 with Standard Mounting Brackets: 2D Drawing

---

# WPS 112-xx QD

URL: https://r2r.tech/documentation/3d-models/wps-112-xx-qd.md

WPS 112-xx QD

---

# WPS 112/221/440/900 or ODC 96/192/288/384/480/768/960 Sensor Installation for to Reduce the Effect of Twist

URL: https://r2r.tech/documentation/manuals/wps-112221440900-or-odc-96192288384480768960-sensor-installation-reduce.md

WPS 112/221/440/900 or ODC 96/192/288/384/480/768/960 Sensor Installation for to Reduce the Effect of Twist

---

# WPS 221 xx-QD

URL: https://r2r.tech/documentation/2d-drawings/wps-221-xx-qd.md

2D Drawing: WPS 221 xx-QD

---

# WPS 221-xx QD

URL: https://r2r.tech/documentation/3d-models/wps-221-xx-qd.md

Roll-2-Roll® Sensor WPS 221-xx QD

---

# WPS 440 xx-QD

URL: https://r2r.tech/documentation/2d-drawings/wps-440-xx-qd.md

2D Drawing: WPS 440 xx-QD

---

# WPS 440-xx QD

URL: https://r2r.tech/documentation/3d-models/wps-440-xx-qd.md

### WPS 440-xx QD


 

---

# WPS 440-xx QD Pixel Location: 2D Drawing

URL: https://r2r.tech/documentation/2d-drawings/wps-440-xx-qd-pixel-location-2d-drawing.md

This 2D drawing provides information about the approximate location of the pixels with respect to the enclosure.

---

# WPS 48-xx QD (1" Mounting)

URL: https://r2r.tech/documentation/3d-models/wps-48-xx-qd-1-mounting.md

WPS 48-IR xx (1" Mounting)

---

# WPS 48-xx QD (No Mounting Bracket)

URL: https://r2r.tech/documentation/3d-models/wps-48-xx-qd-no-mounting-bracket.md

### WPS 48-xx QD (No Mounting Bracket)

---

# WPS 48-xx QD (NW Rail)

URL: https://r2r.tech/documentation/3d-models/wps-48-xx-qd-nw-rail.md

WPS 48-xx QD (NW Rail)

---

# WPS 48-xx QD: 2D Drawing (pdf)

URL: https://r2r.tech/documentation/2d-drawings/wps-48-xx-qd-2d-drawing-pdf.md

WPS 48 Sensor with different mounting options - 2D Drawing

---

# WPS 48: 2D Drawing (DXF)

URL: https://r2r.tech/documentation/2d-drawings/wps-48-2d-drawing-dxf.md

2D dimensional drawing of the WPS 48 Sensor with different mounting options.

---

# WPS 900-xx QD

URL: https://r2r.tech/documentation/3d-models/wps-900-xx-qd.md

WPS 900-xx QD

---

# Can a stepper motor reliably move loads over 10,000 lb for web guiding?

URL: https://r2r.tech/resources/faq/can-stepper-motor-reliably-move-loads-over-10000-lb-web-guiding.md

**Yes.** Roll-2-Roll Technologies stepper-driven actuators routinely move loads exceeding 10,000 lb — and are rated for loads up to **30,000 lb** on precision linear bearings. But the answer requires context, because the question conflates two different numbers.

**Load weight vs. thrust force:** A 15,000 lb roll on a shifting stand sits on linear bearings. The actuator does not lift this weight — it pushes the carriage sideways. The force required to move 15,000 lb on profiled linear rail with an installed friction coefficient of 0.005 is approximately 75 lbf of friction alone. Add inertia, web tension, umbilical drag, and a factor of safety, and the total thrust demand might be 200 to 400 lbf.

A stepper motor producing 7 Nm of torque through a belt-driven ballscrew with a 2:1 reduction can deliver **500 to 2,000 lbf of thrust** depending on the screw lead and configuration. The motor is not straining against 15,000 lb. It is overcoming a few hundred pounds of friction and resistance force — well within its capability with margin to spare.

**Field track record:** Roll-2-Roll Technologies RLA actuators are deployed in **hundreds of installations** across converting, printing, packaging, and nonwoven lines. Many of these installations handle loads of 10,000 to 30,000 lb and have been running continuously for **multiple years** without motor replacement. The key to this reliability is conservative sizing at design time — ensuring the motor never operates near its pull-out torque boundary during normal corrections.

The [actuator sizing calculator](https://r2r.tech/actuator-sizing-calculator) will show you the actual thrust demand for your specific load, bearing type, and operating conditions — and confirm whether the actuator has adequate margin.

---

# Can I retrofit R2R sensors onto existing web guides?

URL: https://r2r.tech/resources/faq/can-i-retrofit-r2r-sensors-existing-web-guides.md

Yes. R2R offers upgrade kits that replace the sensor and controller on existing Fife, AccuWeb, or E+L web guides while keeping the mechanical actuator. Typical retrofit takes 2-4 hours.

---

# Can one controller run sensors for both forward and reverse directions?

URL: https://r2r.tech/resources/faq/can-one-controller-run-sensors-both-forward-and-reverse-directions.md

Yes. The [SCU5](https://r2r.tech/products/sensor-controller/scu5) and [SCU6x](https://r2r.tech/products/sensor-controller/scu6x) controllers can process **two sensors simultaneously** with independent enable/disable control. This is ideal for bidirectional coating machines that run forward and backward between passes.

**Typical dual-sensor configuration:**

- Sensor 1: Mounted on the rewind moving frame—enabled during forward winding
- Sensor 2: Mounted on the fixed machine frame—enabled during reverse (unwind) direction

Instead of repositioning a single sensor when direction changes, operators simply switch which sensor is active via the controller touchscreen or a PLC command over EtherNet/IP, PROFINET, or EtherCAT.

This eliminates sensor repositioning time, enables instant direction changes, and simplifies machine design by removing the need for motorized sensor positioners.

---

# Can Roll-2-Roll actuators replace my existing hydraulic unwind guide system?

URL: https://r2r.tech/resources/faq/can-roll-2-roll-actuators-replace-my-existing-hydraulic-unwind-guide-system.md

Roll-2-Roll Technologies actuators are specifically designed for hydraulic cylinder replacement in unwind and rewind guiding applications:

**What You Eliminate:**

- Hydraulic fluid and the risk of product contamination from leaks
- Filter changes and fluid maintenance (typically 2-4 times per year)
- Seal replacement and valve rebalancing
- Hydraulic power unit (HPU) maintenance and energy costs

**What You Gain:**

- Clean, dry operation—critical for food, pharmaceutical, and medical applications
- Full thrust at zero speed (hydraulics struggle with static positioning)
- Smooth response at variable speeds without the "stick-slip" behavior of hydraulics
- Digital communication via EtherNet/IP, PROFINET, or EtherCAT for integration with modern PLCs

**Retrofit Options:**

- RLA Series: Rotary stepper with belt/pulley and ball screw, thrust up to 2,000 lbf
- BLA Series: Inline stepper with external ball screw for terminal guide applications

Most hydraulic retrofits can be completed in a scheduled maintenance window without major mechanical modifications to the existing stand structure.

---

# Can Roll-2-Roll handle multi-lane cascading alignment?

URL: https://r2r.tech/resources/faq/can-roll-2-roll-handle-multi-lane-cascading-alignment.md

Yes. Roll-2-Roll Technologies systems support multi-lane cascading alignment where each lane's edge position automatically sets the guide point for the next lane.

**Example configuration (14 lanes):**

- Each lane has two sensors: one monitors the "master" edge, one guides the web via a slave guide
- Lane 1's right edge position sets the guide point for Lane 2's slave guide
- Lane 2's right edge sets Lane 3's guide point, and so on
- Result: All lanes maintain edge-to-edge alignment automatically

**For faster response:** The [SCU6x](https://r2r.tech/products/sensor-controller/scu6x) controller's industrial Ethernet connectivity enables a central PLC architecture where any lane change can instantly adjust guide points for all subsequent lanes simultaneously, rather than propagating lane-by-lane.

---

# Can Roll-2-Roll Master/Slave guiding align webs of different widths?

URL: https://r2r.tech/resources/faq/can-roll-2-roll-masterslave-guiding-align-webs-different-widths.md

Yes. This is a unique capability of Roll-2-Roll Technologies Master/Slave guiding that legacy systems cannot match.

By using wide field-of-view sensors ([ODC 480](https://r2r.tech/products/sensors/odc-480), [ODC 768](https://r2r.tech/products/sensors/odc-768), or [ODC 960](https://r2r.tech/products/sensors/odc-960)) that see **both edges** of each web simultaneously, the controller can calculate the centerline of both the Master and Slave webs. It then guides the Slave web so its center aligns with the Master's center.

**Key benefit:** When web widths change, the centerline matching adjusts automatically. Operators no longer need to recalculate and enter new offset values—a tremendous time saver that eliminates a major source of alignment errors.

Example: A 400mm Master web and 350mm Slave web will automatically center-align without any manual intervention.

---

# Can Roll-2-Roll sensors detect splices, flags, and surface defects?

URL: https://r2r.tech/resources/faq/can-roll-2-roll-sensors-detect-splices-flags-and-surface-defects.md

Yes. Because each Roll-2-Roll® sensor is a linear imaging array — not a point sensor — it sees the **full profile of the web** at capture rates up to 1,000 Hz.

Tape splices, operator flags, tears, and voids all change that profile in detectable ways. The sensor and controller identify these changes in real time:

- Splice detection — tape splices and overlaps create a measurable change in the web profile that triggers an alert or output signal
- Flag detection — operator-placed flags and registration marks are detected across a wide sensing window (up to 48 mm for mark detection vs. 2–8 mm for conventional sensors), significantly reducing setup sensitivity
- Tear and void detection — holes, tears, and missing material show up as gaps or profile changes across the pixel array
- Thread and string counting — individual threads are resolved and counted using the sensor resolution (as fine as 0.0635 mm)

The same sensor-controller combination handles these inspection tasks alongside edge guiding or width measurement — no second system, no additional hardware required.

---

# Can Roll-2-Roll sensors work in vacuum environments?

URL: https://r2r.tech/resources/faq/can-roll-2-roll-sensors-work-vacuum-environments.md

[Roll-2-Roll® Sensors](https://r2r.tech/products/sensors) are **vacuum compatible** and can detect clear films in vacuum environments. This is a unique capability that no other edge detection technology can match:

- Ultrasonic sensors cannot function in vacuum—no air means no sound waves for detection
- Many optical sensors struggle with clear films even in normal atmosphere

Roll-2-Roll Technologies fiber-optic technology solves both problems, making it the only solution for applications like:

- Glass manufacturing processes
- Vacuum coating operations
- Semiconductor manufacturing
- Specialty film production

---

# Can Roll-2-Roll® Sensors detect clear or transparent films?

URL: https://r2r.tech/resources/faq/can-roll-2-rollr-sensors-detect-clear-or-transparent-films.md

Yes. [Roll-2-Roll® Sensors](https://r2r.tech/products/sensors) detect clear films using infrared light reflection. Even transparent materials reflect a small amount of infrared light, which the sensors CMOS line camera and adaptive algorithms can reliably detect. This is a key advantage over ultrasonic sensors, which cannot reliably detect clear films, and traditional infrared sensors that require recalibration for different transparency levels.

---

# Can the same Roll-2-Roll® Sensor do both edge guiding AND line guiding?

URL: https://r2r.tech/resources/faq/can-same-roll-2-rollr-sensor-do-both-edge-guiding-and-line-guiding.md

Yes. Unlike competitor systems that require separate sensors for edge detection and line/contrast guiding, a single [Roll-2-Roll® Sensor](https://r2r.tech/products/sensors) handles both functions. The same infrared sensor that detects physical material edges can also detect printed lines, coating edges, and contrast patterns. This dual capability reduces equipment cost and simplifies changeovers—operators don't need to swap sensors when switching between edge-guided and line-guided products.

---

# Do I need a motorized sensor to find and track the line position?

URL: https://r2r.tech/resources/faq/do-i-need-motorized-sensor-find-and-track-line-position.md

No. Traditional line sensors have narrow fields of view, requiring motorized positioning to physically move the sensor until it finds the line. [Roll-2-Roll® Sensors](https://r2r.tech/products/sensors) have wide sensing ranges from 48 mm to 960 mm, allowing the sensor to see the entire potential line position area simultaneously. The sensor and controller automatically identify and track the line within this range—no mechanical movement required.

---

# Do I need a vision expert to set up Roll-2-Roll sensors?

URL: https://r2r.tech/resources/faq/do-i-need-vision-expert-set-roll-2-roll-sensors.md

[Roll-2-Roll® Sensors](https://r2r.tech/products/sensors) are essentially one-dimensional line scan cameras—but without the complexity of traditional machine vision systems:

| Traditional Machine Vision | Roll-2-Roll Technologies Sensors |
| -------------------------- | ------------ |
| Requires separate light source | Integrated LED illumination |
| Needs gantry/mounting systems | Single-sided, compact form factor |
| Requires "vision expert" to program | Operators set up with zero code |
| Complex calibration procedures | No calibration needed |
| Weeks of integration time | Setup in minutes |

This is a major unlock: sophisticated 1D imaging capability that production staff can set up and maintain without specialized training or ongoing support costs.

---

# Do I need to reposition the sensor when changing web widths?

URL: https://r2r.tech/resources/faq/do-i-need-reposition-sensor-when-changing-web-widths.md

No. [Roll-2-Roll® Sensors](https://r2r.tech/products/sensors) are available in apertures from 48mm to 960mm, allowing a single sensor to accommodate a wide range of web widths without repositioning.

For example, an [ODC 288](https://r2r.tech/products/odc-288) sensor can detect edges anywhere within its 288mm (11.3 in) sensing range. Whether you're running a 100mm web or a 250mm web, the sensor detects the edge without adjustment.

This eliminates:

- Changeover time: No 2–5 minute delays for sensor repositioning between SKUs
- Operator error: No risk of incorrect sensor positioning
- Motorized positioners: No additional hardware cost or maintenance

Combined with material-agnostic detection (no recalibration between clear films, opaque substrates, or metallic foils), [Roll-2-Roll® Sensors](https://r2r.tech/products/sensors) enable true "set and forget" operation.

---

# Do I need two sensors for center guiding?

URL: https://r2r.tech/resources/faq/do-i-need-two-sensors-center-guiding.md

Not necessarily. Roll-2-Roll offers two approaches: For wide webs with significant width variation, use two sensors mounted on opposite sides. For narrow to medium webs (up to 960 mm), a single wide sensor like the [ODC 480](https://r2r.tech/products/sensors/odc-480), [ODC 768](https://r2r.tech/products/sensors/odc-768), or [ODC 960](https://r2r.tech/products/sensors/odc-960) can see both edges simultaneously. The single-sensor approach simplifies installation (no alignment between sensors required) and works well for label converting, battery electrode, and narrow web applications.

---

# Do Roll-2-Roll sensors require programming or calibration?

URL: https://r2r.tech/resources/faq/do-roll-2-roll-sensors-require-programming-or-calibration.md

No. Roll-2-Roll® sensors require **zero code and zero calibration**.

Traditional line scan cameras need a vision engineer, custom software, and careful calibration procedures. Roll-2-Roll® sensors take a fundamentally different approach:

- No calibration — the 1:1 magnification of the fiber-optic array means what the sensor sees is exactly what is there. No geometric correction, no lens calibration tables, no distortion compensation.
- No programming — adaptive edge detection algorithms are built into the controller firmware. Operators configure detection parameters through the SCU5 or SCU6x touchscreen interface or the 1DC built-in web interface.
- No vision expertise — setup takes minutes. Select the measurement mode, set thresholds, and the sensor is ready to run.

This simplicity is what makes Roll-2-Roll® sensors practical for inspection applications like splice detection, flag detection, and surface defect monitoring — you get vision-like capabilities without the vision system learning curve.

---

# Do Roll-2-Roll sensors require recalibration when changing materials?

URL: https://r2r.tech/resources/faq/do-roll-2-roll-sensors-require-recalibration-when-changing-materials.md

Unlike traditional sensors that require recalibration for each material type, [Roll-2-Roll® Sensors](https://r2r.tech/products/sensors) use adaptive edge detection algorithms that automatically adjust to different material characteristics.

This eliminates:

- Manual gain adjustments
- Teach mode procedures
- Operator-dependent settings
- Extended changeover times

**The impact:** Plants using legacy sensors typically lose 2 hours monthly to recalibration—time that Roll-2-Roll Technologies technology completely eliminates.

---

# Does line/contrast guiding require a different sensor than edge guiding?

URL: https://r2r.tech/resources/faq/does-linecontrast-guiding-require-different-sensor-edge-guiding.md

No. With [Roll-2-Roll® Sensors](https://r2r.tech/products/sensors), you do not need to purchase or install a separate sensor for line/contrast guiding. The same ODC or 1DC sensor family handles edge detection, line guiding, center guiding, and contrast guiding. For most high-contrast applications, the standard infrared light source works for both edge and line detection. For low-contrast or UV-printed lines, white light or UV light source options are available.

---

# Does R2R sensor work on clear/transparent films?

URL: https://r2r.tech/resources/faq/does-r2r-sensor-work-cleartransparent-films.md

Yes. R2R fiber-optic sensors detect edges on clear films (PET, BOPP, cellophane) as accurately as opaque materials. The light scattering technology responds identically to any material—no special settings or sensors required.

---

# How accurate are Roll-2-Roll® Sensors?

URL: https://r2r.tech/resources/faq/how-accurate-are-roll-2-rollr-sensors.md

[Roll-2-Roll® Sensors](https://r2r.tech/products/sensors) achieve 0.0635 mm (0.0025 in) hardware resolution with repeatability greater than 99.9%. This precision is maintained across all material types without recalibration. For comparison, this resolution is approximately the thickness of a human hair. The sensors also feature linearity error of less than 0.25% across the full sensing range.

---

# How do I determine the right actuator size for my unwind or rewind web guide?

URL: https://r2r.tech/resources/faq/how-do-i-determine-right-actuator-size-my-unwind-or-rewind-web-guide.md

Actuator sizing starts with one question: **how much force does the actuator need to produce** to move your guide or shifting stand reliably? The answer depends on more than just the weight on the bearings.

Roll-2-Roll Technologies uses a **6-term force model** that accounts for every significant resistance the actuator must overcome:

- Bearing friction — the dominant term for heavy loads on linear bearings
- Inertia — force to accelerate the mass at your target correction rate
- Web tension lateral component — the sideways pull from web wrap angle on guide rollers
- Umbilical drag — hoses, cables, and air lines that resist carriage motion
- Floor grade — gravity component if the travel axis is not perfectly level
- Misalignment friction — additional drag from rail or bearing misalignment

Our [actuator sizing calculator](https://r2r.tech/actuator-sizing-calculator) offers two approaches:

- Simple mode — enter load weight and bearing type for a quick estimate. Uses a factor of safety of 2.0 or higher to compensate for forces not explicitly modeled.
- Detailed mode — model all six force terms individually for a precise result, typically with a factor of safety of 1.5 to 1.75.

If you want a reality check before running the calculator, try a **spring-scale pull test**: attach a calibrated spring scale to the carriage and pull horizontally at a steady, slow rate. The peak reading gives you the actual installed friction force — often 2 to 5 times the catalog bearing friction value.

For a deeper walkthrough of the force model and worked examples, see the full [actuator sizing technical article](https://r2r.tech/actuator-sizing-article).

---

# How do I handle width changeovers?

URL: https://r2r.tech/resources/faq/how-do-i-handle-width-changeovers.md

Simply adjust the "guide point" on the SCU6x touchscreen. The sensor stays fixed—no mechanical repositioning required. Width changeovers take seconds, not minutes.

---

# How do I select the right sensor size for center guiding?

URL: https://r2r.tech/resources/faq/how-do-i-select-right-sensor-size-center-guiding.md

Calculate the sensor field of view needed: (1) Find total width change (max width - min width), (2) Divide by 2 (change per side), (3) Add wander delta (typically ±10-25mm safety margin), (4) Select the next larger sensor. For example, if running webs from 400-500mm with ±15mm wander: Total change = 100mm ÷ 2 = 50mm per side, plus 15mm wander = 65mm needed. Choose the [ODC 96](https://r2r.tech/products/sensors/odc-96) (96mm window) as the [ODC 48](https://r2r.tech/products/sensors/odc-48) would be too small.

---

# How do I size an actuator for an unwind guiding application?

URL: https://r2r.tech/resources/faq/how-do-i-size-actuator-unwind-guiding-application.md

Sizing an unwind actuator requires more than knowing the total load weight. The key factors are:

1. Breakaway Force: The actuator must overcome static friction to start movement. This depends on the bearing type:

Low-friction linear rail bearings (coefficient ~0.01): A 10,000 lb load requires only ~100 lbf to start moving
2. Sliding shaft bearings (coefficient ~0.25): The same 10,000 lb load requires ~2,500 lbf
3. Acceleration Requirements: Higher acceleration for faster response requires proportionally more thrust
4. Safety Factor: Include 20-30% margin for binding, misalignment, and wear

**Recommendation:** Always use low-friction linear rail bearings. The cost savings on a smaller actuator typically exceeds the bearing cost difference, plus you get better dynamic response.

Roll-2-Roll Technologies RLA and BLA series actuators provide thrust from 50 lbf to 2,000 lbf, handling loads up to 30,000 lbs when paired with proper bearing systems.

---

# How do Roll-2-Roll sensors connect to my PLC or industrial network?

URL: https://r2r.tech/resources/faq/how-do-roll-2-roll-sensors-connect-my-plc-or-industrial-network.md

Roll-2-Roll® sensors offer two integration paths, both providing real-time edge positions, width measurements, and inspection alerts to your PLC without middleware or custom drivers.

### 1DC Sensors — Direct PLC Connection

The 1DC has a built-in controller with an M8 4-pin network connector. It connects directly to your industrial Ethernet network via:

- EtherNet/IP
- PROFINET
- EtherCAT
- Modbus/TCP
- CC-Link IE Field Basic

This makes the 1DC ideal for OEMs and integrators who want a single-device solution with direct PLC communication.

### ODC Sensors — Via SCU5 or SCU6x Controller

ODC sensors connect to an SCU5 or SCU6x controller via M12 12-pin Quick Disconnect Sensor Cable (up to 10 m). The controller then provides the network interface:

- SCU6x — dual industrial Ethernet ports, 4 digital inputs (NPN/PNP/dry contact), 3 digital outputs, plus web browser dashboard for remote diagnostics
- SCU5 — single Ethernet port (EtherNet/IP, PROFINET, or EtherCAT depending on variant) plus analog outputs (±10V, 0–20 mA)

Both paths deliver edge positions, width data, and inspection signals — including splice alerts, flag detection triggers, and defect notifications — directly to Rockwell, Siemens, Beckhoff, or any EtherNet/IP-compatible PLC.

---

# How do Roll-2-Roll sensors keep coating heads aligned in battery electrode manufacturing?

URL: https://r2r.tech/resources/faq/how-do-roll-2-roll-sensors-keep-coating-heads-aligned-battery-electrode-manufacturing.md

In Li-Ion battery electrode coating, the coating must align precisely with the current collector foil. Steering the foil creates stress and wrinkles that cause defects. Instead, [Roll-2-Roll® Sensors](https://r2r.tech/products/sensors) enable coating head chasing:

- Sensor placement: [ODC 96](https://r2r.tech/products/sensors/odc-96) or similar mounts directly on the coating carriage
- Edge tracking: The sensor continuously monitors the foil edge position
- Dynamic alignment: If the foil drifts, the coating head moves to follow—maintaining bead position within ±0.1mm

**The benefit:** No mechanical stress on the foil, no wrinkles, no electrode misalignment. This is critical for preventing lithium plating defects in finished cells.

---

# How do stepper motors compare to BLDC motors for web guiding actuators?

URL: https://r2r.tech/resources/faq/how-do-stepper-motors-compare-bldc-motors-web-guiding-actuators.md

This is a fair question that deserves a fair answer. Both stepper motors and brushless DC (BLDC) motors with field-oriented control (FOC) are viable drive technologies for web guiding actuators. Each has genuine strengths, and the best choice depends on what you prioritize.

**Where steppers win:**

- Zero field tuning — stepper parameters are set at the factory for worst-case conditions. No auto-tune, no gain adjustment, no commissioning procedure at the machine.
- No encoder required — the web sensor closes the position loop externally, so shaft feedback is unnecessary for position accuracy.
- Native holding torque — steppers hold position at rest without a position loop or brake.
- Lower cost — motor, driver, and system cost are typically lower than equivalent BLDC with FOC drive and encoder.

**Where BLDC with FOC wins:**

- Energy efficiency — FOC BLDC draws current proportional to load; steppers draw set current regardless of load, wasting energy as heat at rest.
- Higher speed capability — BLDC torque holds up better at higher speeds than stepper torque, which drops off above moderate RPM.
- Lower noise — FOC produces smooth, quiet rotation; steppers are audibly louder, especially at resonance speeds.
- High duty cycle thermal performance — BLDC runs cooler under continuous rapid cycling.
- Smoother motion — sinusoidal commutation eliminates the torque ripple inherent in stepper microstepping.

**The Roll-2-Roll Technologies rationale:** Web guiding corrections are slow (0.5 to 2 Hz), the motor rests most of the time, and Roll-2-Roll Technologies ships actuators as OEM products to facilities without motion control expertise. In this context, the stepper's zero-tuning, plug-and-play simplicity outweighs the BLDC's efficiency and speed advantages. If your application involves high duty cycles, continuous high-speed correction, or noise-sensitive environments, a BLDC solution may be worth the added commissioning complexity.

---

# How does electronic guide point adjustment benefit product changeovers?

URL: https://r2r.tech/resources/faq/how-does-electronic-guide-point-adjustment-benefit-product-changeovers.md

Electronic guide point adjustment drastically simplifies product changeovers by eliminating the need for operators to physically reposition sensors when the web width changes. Instead of unlocking, moving, and re-locking a sensor hardware assembly, the operator simply changes the target position setting on the controller's touchscreen interface. Better yet with [Roll-2-Roll® Controllers](https://r2r.tech/products/controllers) this can be completely automated with remote guidepoint adjustment either via industrial ethernet or digital I/O inputs.

Electronic guide point offers three specific benefits for product changeovers:

1. Elimination of Mechanical Adjustments & Safety Risks: In traditional "single edge guiding," a width change requires the sensor to be physically moved to the new edge location. This often forces operators to climb into the machine or reach into hazardous areas to adjust brackets. By using [Roll-2-Roll® Sensor](https://r2r.tech/products/sensors) (e.g., 48mm to 960mm sensing window), the sensor remains fixed to the machine frame, and the "guide point" is moved electronically within the sensor's viewing window. This removes the operator from the machine, improving plant safety.
2. Reduction of Operator Error & Waste: Physical sensor repositioning is prone to human error. If an operator locks the sensor in the slightly wrong position, or if the sensor bracket is not rigid, the web will be aligned incorrectly, leading to immediate material waste. Electronic adjustment allows for precise, digital settings (e.g., 0.25mm increments with [Roll-2-Roll® Controller](https://r2r.tech/products/controllers)) that are repeatable. Furthermore, these settings can be pre-programmed based on product codes, allowing for "recipe-based" changeovers where the guide point updates automatically without human intervention.
3. Removal of Mechanical Wear: Legacy systems sometimes use "sensor positioners" (electromechanical actuators that move the sensors) to automate this process. However, these introduce additional moving parts, maintenance requirements, and mechanical wear and tear. Electronic guide point adjustment achieves the same result mathematically using software and wide sensors, completely removing the need for mechanical sensor chasing mechanisms.

---

# How does Roll-2-Roll achieve slit-to-feature registration on converting lines?

URL: https://r2r.tech/resources/faq/how-does-roll-2-roll-achieve-slit-feature-registration-converting-lines.md

In slit-to-feature applications, the cut must align with artwork or a printed line on the web—not the web edge. [Roll-2-Roll® Sensors](https://r2r.tech/products/sensors) enable this through dynamic tool tracking:

1. Sensor mounting: The [ODC 96](https://r2r.tech/products/sensors/odc-96) or [ODC 192](https://r2r.tech/products/sensors/odc-192) sensor attaches directly to the knife holder bracket
2. Target acquisition: The sensor locks onto the printed line, coating edge, or contrast feature
3. Chasing: As the feature wanders, the controller drives the knife carriage laterally until the sensor re-aligns—maintaining ±0.0635mm registration

**Why this matters:** Print position varies relative to web edges due to registration error at the press. Standard edge guiding cannot solve this—the slitter must chase the print.

---

# How does Roll-2-Roll eliminate hydraulic maintenance on rewind guides?

URL: https://r2r.tech/resources/faq/how-does-roll-2-roll-eliminate-hydraulic-maintenance-rewind-guides.md

Roll-2-Roll Technologies rewind guides use **electromechanical actuators** (RLA and BLA series) instead of traditional hydraulic cylinders. This completely eliminates:

- Hydraulic fluid—no oil to leak, change, or dispose of
- Filters and seals—no consumables to replace quarterly
- Valve balancing issues—no unequal extension/retraction speeds
- Contamination risk—critical for food, pharmaceutical, and medical applications
- Hydraulic pumps—quieter operation without pump noise

Typical plants using hydraulic systems report spending 10–20 hours annually on rewind guide maintenance alone. Electromechanical systems reduce this to near-zero, with only periodic inspection required.

The [SCU6x](https://r2r.tech/products/sensor-controller/scu6x) controller includes an integrated motor driver, eliminating the need for separate drive cabinets and simplifying installation.

---

# How does the belt-driven ballscrew design in RLA actuators convert motor torque to linear thrust?

URL: https://r2r.tech/resources/faq/how-does-belt-driven-ballscrew-design-rla-actuators-convert-motor-torque-linear.md

The RLA actuator converts rotary stepper motor torque into linear thrust using a **belt-driven ballscrew** (or roller screw) mechanism. The conversion follows a straightforward mechanical relationship.

The thrust scalar **k** relates motor torque to linear force:

**k = Rbelt × (2π / L) × η**

Where:

- Rbelt — belt reduction ratio (driven pulley teeth / motor pulley teeth). A 2:1 ratio doubles the effective torque at the screw.
- L — screw lead (linear travel per revolution), in meters. Smaller lead = higher force multiplication but lower speed.
- η — drivetrain efficiency, typically 0.85 to 0.90 for a ball screw with belt drive.

The belt reduction stage serves two purposes: it **amplifies torque** delivered to the screw, and it **reduces reflected load inertia** back to the motor by the square of the reduction ratio. Both effects allow a moderately sized stepper motor to produce thrust levels (800 to 2,000 lbf) that would otherwise require a much larger motor.

**The compliance tradeoff — honestly:** A belt introduces slight mechanical compliance compared to a direct-coupled design. Under sudden load changes, the belt stretches microscopically before the screw sees the full force. For high-bandwidth servo positioning, this would be a problem. For web guiding — where correction rates are 0.5 to 2 Hz and the web sensor outer loop corrects any residual error — this compliance is inconsequential. The belt's benefits (torque amplification, inertia reduction, compact packaging) far outweigh the compliance penalty at web guiding speeds.

The [actuator sizing calculator](https://r2r.tech/actuator-sizing-calculator) uses this equation internally, with the correct k values for each RLA model, so you do not need to calculate it manually.

---

# How is a Roll-2-Roll sensor different from a traditional line scan camera?

URL: https://r2r.tech/resources/faq/how-roll-2-roll-sensor-different-traditional-line-scan-camera.md

Both Roll-2-Roll® sensors and traditional line scan cameras capture one-dimensional scans to build profiles of continuously moving webs. However, Roll-2-Roll® sensors use patented linear fiber-optic arrays instead of circular lenses. This fundamental difference delivers several advantages:

- 100x more light sensitivity — larger pixels (63.5 µm vs. 5–14 µm in conventional cameras) capture significantly more light per pixel
- Working distance under 15 mm — the 1:1 magnification of fiber optics enables compact installations in tight spaces
- Zero lens distortion — linear fiber optics behave like telecentric lenses, eliminating the aberrations and geometric errors inherent in circular optics
- No vision engineer required — adaptive edge detection algorithms are built in, so setup takes minutes instead of the weeks typically required for traditional line scan camera integration

The result is line-scan-camera-grade measurement capability — pixel counts from 768 to over 14,000, scan rates above 200 kHz — without calibration, custom software, or specialized imaging expertise.

---

# How long does it take to set up an Roll-2-Roll® Web Guides?

URL: https://r2r.tech/resources/faq/how-long-does-it-take-set-roll-2-rollr-web-guides.md

[Roll-2-Roll® Web Guides](https://r2r.tech/products/web-guides) can be set up in minutes, not hours. The sensors Auto-Setup function detects the web edge automatically without manual threshold adjustment, menu navigation, or stopping the machine. This is particularly valuable for converters running short production runs with frequent changeovers—there is no need to move sensors or recalibrate when switching materials or web widths.

---

# How many sensors can one Roll-2-Roll controller process for Master/Slave guiding?

URL: https://r2r.tech/resources/faq/how-many-sensors-can-one-roll-2-roll-controller-process-masterslave-guiding.md

Both [SCU5](https://r2r.tech/products/sensor-controller/scu5) and [SCU6x](https://r2r.tech/products/sensor-controller/scu6x) controllers support **two independent sensor channels**, enabling single-controller Master/Slave configurations:

- Channel 1: Master sensor (monitors reference web position)
- Channel 2: Slave sensor (provides feedback for the guided web)

For multi-slave applications (3+ webs), the Master signal can be broadcast to multiple Slave controllers via industrial Ethernet (EtherNet/IP, PROFINET, EtherCAT, or Modbus/TCP). This enables scalable synchronization—one Master can drive any number of Slaves without mechanical complexity.

---

# How much does legacy edge sensor calibration cost annually?

URL: https://r2r.tech/resources/faq/how-much-does-legacy-edge-sensor-calibration-cost-annually.md

The cost of continuing with legacy edge sensors includes:

#### Hidden Costs (Uncounted but Real)

- Calibration Labor: 2 hours monthly at $60/hour = $1,440/year per line
- Extended Changeovers: 2 extra minutes × 5 changes/day × 250 days at $1,000/hour = $41,700/year
- Troubleshooting Time: 4 hours/month diagnosing drift-related issues = $2,880/year

#### Risk Costs

- Quality Escapes: Undetected edge drift causing coating misregistration
- Equipment Damage: Missed edges leading to web wraps and bearing damage

#### Opportunity Costs

- Material Limitations: Cannot run clear films, mesh, or specialty materials
- Speed Constraints: Slow sensor response forces reduced line speeds

**Typical Annual Cost of Inaction: $25,000 - $75,000 per line**

---

# How much downtime do width changes cause with moving sensor systems?

URL: https://r2r.tech/resources/faq/how-much-downtime-do-width-changes-cause-moving-sensor-systems.md

Every width change with traditional moving sensor center guides requires waiting for mechanical positioners to reposition both sensors to the new edge locations. Depending on the distance to travel and motor speed, this can take several seconds to over a minute per changeover. For converters running short production runs with 10-20 width changes per shift, this accumulated downtime can total 30+ minutes daily. Roll-2-Roll wide [Roll-2-Roll® Sensors](https://r2r.tech/products/sensors) handle width changes electronically in milliseconds with zero repositioning delay.

---

# Is a Roll-2-Roll sensor just a basic edge sensor?

URL: https://r2r.tech/resources/faq/roll-2-roll-sensor-just-basic-edge-sensor.md

No. A Roll-2-Roll® sensor is actually a line scan camera with vision-like capabilities, packaged with the simplicity of a sensor.

Traditional edge sensors give you a single-point measurement — one edge position, one signal. Roll-2-Roll® sensors have 768 to over 14,000 pixels, integrated LED lighting (infrared, ultraviolet, or white light options), and adaptive algorithms that provide **spatial awareness** across the full sensing range.

This means a single Roll-2-Roll® sensor can handle:

- Edge detection — up to 128 edges simultaneously
- Width measurement — real-time, across ranges up to 960 mm
- Splice detection — tape splices, overlaps, and joints
- Flag detection — operator flags, markers, and registration marks
- Thread counting — individual thread or string detection
- Tear and void inspection — holes, tears, and surface anomalies

All of this without machine vision complexity. The same sensor-controller combination can be repurposed across entirely different applications without hardware replacement — significantly reducing ownership costs.

---

# What are the primary advantages of center guiding?

URL: https://r2r.tech/resources/faq/what-are-primary-advantages-center-guiding.md

Here are the primary advantages of center guiding:

### Inherent Error Reduction (Averaging Effect)

The most distinct technical advantage of center guiding is that it averages the position of both web edges. By calculating the centerline based on inputs from two sensors (or one wide [Roll-2-Roll® Sensor](https://r2r.tech/products/sensors)), the system inherently filters out edge imperfections.

- Fuzzy or Serrated Edges: If a web has rough, serrated edges (common in extrusion or nonwovens), a single-edge guide might oscillate as it tries to trace the jagged profile. Center guiding averages the left and right edge positions, smoothing out these variations and stabilizing the web.
- Wrinkles: Wrinkles effectively reduce the web width by pulling the edges inward. While a single-edge sensor might interpret a wrinkle as a position error and move the guide unnecessarily, center guiding sees the width change on both sides and maintains the centerline, reducing oscillation.
- Variable Opacity/Porosity: For materials that allow light to leak through (like nonwovens), legacy sensor readings can fluctuate. Center guiding significantly reduces the standard deviation of these errors compared to single-edge guiding. However, with [Roll-2-Roll® Sensor](https://r2r.tech/products/sensors) this is not a problem.

### Simplified Width Changeovers

In single-edge guiding, any change in web width requires the operator to physically move the sensor to the new edge location to maintain alignment. Center guiding eliminates this requirement for centered processes.

- No Sensor Repositioning: If the sensors are equidistant from the machine centerline and a wide sensor like [Roll-2-Roll® Sensor](https://r2r.tech/products/sensors) is used, the web width can change (e.g., from a wide master roll to a narrower roll) without requiring the operator to move the sensors or adjust the guide point. The centerline remains constant relative to the machine. For legacy horseshoe/fork sensors it is important to ensure that width change does not snag the web. This is not an issue with [Roll-2-Roll® Sensors](https://r2r.tech/products/sensors) since they are single sided. 
- Elimination of Mechanical Positioners: Traditional systems often required complex "sensor positioners" (motorized lead screws) to physically move sensors during width changes. Modern wide-sensor center guiding eliminates these moving parts, reducing mechanical wear and maintenance.

### Simultaneous Process Monitoring

Because center guiding requires the detection of both web edges, it provides valuable secondary data that single-edge systems cannot:

- Width Measurement: The system can calculate and monitor the real-time width of the web while guiding it. This data can be used for quality control purposes.
- Web Break Detection: The presence of two sensors (or a wide field of view sensor) acts as a redundant web presence check. If the web breaks, the system knows immediately because it loses both edges, functioning as an inherent web break detector.

### Process alignment

Center guiding is the standard requirement when downstream processes (such as printing, coating, or lamination) must be aligned to the middle of the machine rather than a specific edge. It ensures that despite variations in the incoming roll's width, the material remains centered relative to the tool or die or the print system.

---

# What are the primary differences between terminal and intermediate guides?

URL: https://r2r.tech/resources/faq/what-are-primary-differences-between-terminal-and-intermediate-guides.md

### Location and Function

- Terminal Guides: These are located at the very entry (unwind) and exit (rewind) of a roll-to-roll machine. Their purpose is to manage the master roll—either ensuring the web feeds correctly into the machine (unwind) or ensuring the roll winds up straight out of the machine (rewind).
- Intermediate Guides: These are located within the interior of the machine, typically just before a critical process such as printing, coating, laminating, or slitting. Their job is to shift the running web to align it for that specific downstream process.

### Mechanism of Movement

- Terminal (Moving the Roll): Terminal guides function by moving the entire roll of material laterally. They typically utilize a "shifting stand" or "shifting base" on linear bearings to position the heavy unwind or rewind rolls.
- Intermediate (Moving the Web): Intermediate guides function by twisting or bending the web itself while the machine frame stays stationary. Mechanisms like Displacement Guides or Steering Guides displace the web by rotating or translating rollers over which the web passes.

### Dynamics and Application

- Unwind vs. Rewind Dynamics:Unwind Guides: Function as true guides. They shift the unwind stand to ensure the web enters the machine at a predetermined position.
- Rewind Guides: Function as chasing systems. They do not control the web's lateral position; instead, the rewind stand moves to align the winding roll with the incoming web edge to ensure a straight roll.

**Intermediate Dynamics:** Most intermediate guides (specifically Displacement and Steering guides) rely on the [Normal Entry Rule](https://r2r.tech/node/699), which states that a web will align itself perpendicular to the axis of the roller it is approaching.

### Sensor Placement

- Terminal Guides:Unwind: The sensor must be fixed to the machine frame (it does not move with the stand) and positioned immediately downstream of the shifting idler,.
- Rewind: The sensor must be attached to the moving rewind stand so it moves with the carriage to "chase" the web.

**Intermediate Guides:** The sensor is always located in the **exit span** (the span immediately following the guide roller) and moves with the web, not the guide mechanism. It should be placed as close to the exit roller as possible.

### Actuator Requirements

- Terminal Guides: Because they often move heavy master rolls (potentially thousands of pounds), they typically require high-thrust actuators and robust mechanical rigidity to avoid resonance.
- Intermediate Guides: These move lighter guide frames and rollers, focusing more on dynamic response and low friction than raw thrust.

---

# What bearing friction coefficient should I use for actuator sizing?

URL: https://r2r.tech/resources/faq/what-bearing-friction-coefficient-should-i-use-actuator-sizing.md

Bearing friction is typically the **largest single force term** in an actuator sizing calculation, and getting the friction coefficient right matters more than any other input.

**Catalog values by bearing type:**

- Profiled linear rail (recirculating ball) — μ = 0.003 to 0.005
- Cam rollers on steel plate — μ = 0.002 to 0.005
- Plain bronze bushings — μ = 0.10 to 0.20
- PTFE-lined bushings — μ = 0.04 to 0.10
- Roller bearings (cylindrical) — μ = 0.005 to 0.010

**The critical reality: installed friction is 2 to 5 times catalog values.**

Catalog friction coefficients represent clean, properly lubricated, perfectly aligned bearings under controlled conditions. In a production environment, actual friction is higher due to:

- Contamination (dust, web debris, adhesive residue)
- Inadequate or degraded lubrication
- Rail or bearing misalignment from installation tolerances
- Preload variation from mounting surface flatness
- Side-loading from web tension or mechanical misalignment

The Detailed calculator includes a **kinstall** multiplier (default 2.0 to 3.0) that scales catalog friction to installed conditions. This is the single most important correction factor in the model.

**Best practice: spring-scale pull test.** Attach a calibrated spring scale to the carriage and pull horizontally at a slow, steady rate. The peak reading is your actual installed friction force. This 5-minute test eliminates the largest source of sizing uncertainty and is far more reliable than estimating from catalog values. If you can measure it, measure it.

Use the [actuator sizing calculator](https://r2r.tech/actuator-sizing-calculator) with measured pull-test values in Detailed mode for the most accurate sizing result.

---

# What causes telescoped rolls and how does Roll-2-Roll prevent them?

URL: https://r2r.tech/resources/faq/what-causes-telescoped-rolls-and-how-does-roll-2-roll-prevent-them.md

Telescoped (uneven) roll edges typically result from:

- Response lag: Hydraulic systems have inherent lag from valve response and fluid compressibility. By the time the guide reacts, the web has already wandered.
- Valve balancing issues: Unequal extension/retraction speeds cause inconsistent correction.
- Improper sensor mounting: If the sensor is fixed to the floor instead of the moving stand, or if the mounting arm is flexible, the system receives incorrect position feedback.

**The Roll-2-Roll Technologies solution:**

- Zero-backlash actuators: Electromechanical actuators respond immediately without the "spongy" feel of hydraulics
- Stiff control loop: Fast response prevents lag-induced wander, especially on outer roll layers
- Proper mounting guidance: Sensor on the moving stand, observing web at a fixed upstream idler, with structurally rigid mounting

The result is perfectly straight-sided rolls without the "drift" that causes telescoping during shipping and handling.

---

# What factor of safety should I use when sizing a web guiding actuator?

URL: https://r2r.tech/resources/faq/what-factor-safety-should-i-use-when-sizing-web-guiding-actuator.md

The factor of safety (FoS) in actuator sizing serves a specific purpose: it provides margin for forces and conditions that are **not fully captured by the model**. The right FoS depends on how many of those forces you have actually modeled.

**Simple mode — FoS 2.0 or higher:**

The Simple calculator models only bearing friction and inertia. It does not account for web tension lateral forces, umbilical drag, floor grade, or bearing misalignment. An FoS of 2.0 compensates for these unmodeled terms. If you suspect unusually high secondary forces (heavy cable bundles, steep floor grade, old bearings), consider FoS 2.5 or higher.

**Detailed mode — FoS 1.5 to 2.0:**

The Detailed calculator models all six force terms explicitly: bearing friction, inertia, web tension lateral component, umbilical drag, floor grade, and misalignment. Because the model is more complete, a lower FoS is justified — typically 1.5 to 1.75. An FoS of 2.0 in Detailed mode is conservative and appropriate for critical applications or uncertain input values.

**What the FoS covers in each case:**

- Simple mode FoS — compensates for missing force terms plus measurement uncertainty
- Detailed mode FoS — compensates primarily for measurement uncertainty, bearing condition variation, and transient load spikes

A common mistake is applying an FoS to compensate for terms you *should* be modeling. If you know the web tension and wrap angle, model the lateral force directly in Detailed mode rather than inflating the FoS in Simple mode. The FoS should cover **unknowns, not missing terms**.

When in doubt, use the [actuator sizing calculator](https://r2r.tech/actuator-sizing-calculator) in both modes and compare results. If they diverge significantly, the secondary forces are meaningful and Detailed mode gives the more accurate answer.

---

# What happens if the web jumps suddenly during chasing—won't the sensor lose track?

URL: https://r2r.tech/resources/faq/what-happens-if-web-jumps-suddenly-during-chasing-wont-sensor-lose-track.md

In chasing applications, process upsets can cause the web to wander significantly—due to splice passage, tension changes, or roll eccentricity. This exposes a critical weakness in narrow-range sensors:

- Narrow sensor problem: If the target (line, edge, or pattern) moves outside the sensor's field of view, the system loses tracking. With older controllers lacking edge-loss protection, the actuator continues driving in one direction until it reaches its limit—potentially damaging equipment or producing scrap.
- [Roll-2-Roll® Sensors](https://r2r.tech/products/sensors) + [SCU5](https://r2r.tech/products/sensor-controller/scu5)/[SCU6x](https://r2r.tech/products/sensor-controller/scu6x) advantage: Wide-range sensors (up to 960mm) provide a large capture window that maintains lock on the target during extreme wander events. Additionally, the [SCU5](https://r2r.tech/products/sensor-controller/scu5) and [SCU6x](https://r2r.tech/products/sensor-controller/scu6x) controllers include a "Lock on Lost Edge" feature that inhibits actuator movement if the edge is lost—preventing runaway conditions. For line/contrast guiding, loss of contrast also inhibits the actuator.

**Example:** An [ODC 288](https://r2r.tech/products/odc-288) sensor provides 288mm of sensing range. If the web edge wanders ±100mm during a splice, the sensor never loses sight of it—and the controller keeps tracking smoothly.

---

# What happens when the printed line is intermittent, such as gaps between labels?

URL: https://r2r.tech/resources/faq/what-happens-when-printed-line-intermittent-such-gaps-between-labels.md

The [Roll-2-Roll® Controller](https://r2r.tech/products/controllers) includes Loss of Contrast Logic specifically for this situation. When the sensor encounters a gap where the tracked feature disappears (such as the space between labels), the web guide holds its current position. When the sensor sees the same feature again—matching the width and hue characteristics taught during setup—tracking resumes automatically. This prevents the "hunting" or crashing behavior common with traditional line sensors.

---

# What is center guiding?

URL: https://r2r.tech/resources/faq/what-center-guiding.md

Center guiding is a web handling technique that maintains the centerline of a moving web by detecting both edges simultaneously and calculating the average position. Unlike single-edge guiding, center guiding systems use two sensors (or one wide sensor that sees both edges) to compute the true centerline regardless of web width variations. This approach naturally filters out edge defects and wrinkles, providing more stable control than single-edge systems.

---

# What is edge guiding?

URL: https://r2r.tech/resources/faq/what-edge-guiding.md

Edge guiding is a web handling technique that maintains the lateral position of a continuous web by sensing the edge position and automatically steering the web back on course. Edge guiding systems consist of three components: a sensor to detect the web edge, a controller to process the position data, and an actuator to physically move the web or guide mechanism. The web aligns according to the Normal Entry Rule—it naturally aligns perpendicular to the axis of rotation of the roller it approaches.

---

# What is fork sensor collision and how does Roll-2-Roll® Sensor avoid it?

URL: https://r2r.tech/resources/faq/what-fork-sensor-collision-and-how-does-roll-2-rollr-sensor-avoid-it.md

Fork sensor collision occurs when the web width increases unexpectedly (due to material variation, tension changes, or process adjustments) and the expanding web physically contacts the fork-style sensor assembly. This causes web damage (scratches, contamination), sensor damage (misalignment or breakage), emergency line stops, and material waste. [Roll-2-Roll® Sensors](https://r2r.tech/products/sensors) avoids this entirely by using wide one-sided sensor mounted outside the web path—even when web width increases dramatically, there is no physical sensor in the way.

---

# What is the accuracy of Roll-2-Roll edge sensors?

URL: https://r2r.tech/resources/faq/what-accuracy-roll-2-roll-edge-sensors.md

[Roll-2-Roll® Sensors](https://r2r.tech/products/sensors) provide true spatial awareness—not just binary on/off detection:

| Hardware Resolution | 0.0635 mm (0.0025 in) |
| ------------------- | --------------------- |
| Firmware Resolution | Up to 0.015875 mm |
| Repeatability | >99.9% |
| Linearity Error |  |
| Response Time | 20 ms standard (1 ms available) |

This accuracy is maintained across all material types without recalibration—critical for precision applications like battery electrode coating, optical film production, and high-speed converting.

---

# What is the advantage of Roll-2-Roll® Sensors for center guiding?

URL: https://r2r.tech/resources/faq/what-advantage-roll-2-rollr-sensors-center-guiding.md

[Roll-2-Roll® Sensors](https://r2r.tech/products/sensors) eliminate the need for mechanical sensor positioners—motorized assemblies that move sensors to chase edge positions. Traditional center guiding requires sensor positioners because narrow sensors cannot see both edges when web width changes. These positioners introduce motors, lead screws, and sliding brackets that jam, wear out, and require maintenance. [Roll-2-Roll® Sensors](https://r2r.tech/products/sensors) have wide fields of view (48-960 mm) allowing them to track width variations electronically without moving parts, eliminating a major category of mechanical failures and maintenance.

---

# What is the difference between mechanical and electronic Master/Slave guiding?

URL: https://r2r.tech/resources/faq/what-difference-between-mechanical-and-electronic-masterslave-guiding.md

**Mechanical Master/Slave (legacy):** The Master sensor is mounted on a motorized slide that physically chases the web position. The Slave sensor is mechanically linked to move the same distance. This creates wear parts, lag, and "loop within a loop" tuning problems.

**Electronic Master/Slave (Roll-2-Roll Technologies):** Both sensors connect to a single controller. The controller reads the Master position and electronically adjusts the Slave guide point in real-time—no physical sensor movement. This eliminates mechanical lag, wear parts, and tuning instability.

The electronic approach also enables capabilities impossible with mechanical systems, such as centerline matching between webs of different widths.

---

# What is the difference between the ODC Family and 1DC Series for edge detection?

URL: https://r2r.tech/resources/faq/what-difference-between-odc-family-and-1dc-series-edge-detection.md

Both product lines provide the same edge detection accuracy and material versatility. The difference is in how they integrate:

#### [ODC 96](https://r2r.tech/products/sensors/odc-96) Family

- Best for: End users who want easy setup with touchscreen interface
- Requires [SCU5](https://r2r.tech/products/sensor-controller/scu5) or [SCU6x](https://r2r.tech/products/sensor-controller/scu6x) controller
- Intuitive touchscreen operation
- No coding required
- Sensing ranges: 48-960mm

#### [1DC 960](https://r2r.tech/products/sensors/roll-2-rollr-sensor-1dc-960) Series

- Best for: OEMs and technical users who prefer Ethernet/PLC interfaces
- All-in-one sensor (no external controller needed)
- Direct Ethernet connectivity
- EtherNet/IP, PROFINET, EtherCAT, Modbus/TCP
- Sensing ranges: 96-960mm

Both are priced similarly—choose based on your integration preference, not cost.

---

# What is the difference between the ODC Family and 1DC Series for edge guiding?

URL: https://r2r.tech/resources/faq/what-difference-between-odc-family-and-1dc-series-edge-guiding.md

Both use the same fiber-optic sensing technology and achieve identical accuracy. The **ODC Family** requires an external controller (SCU5 or SCU6x) with a touchscreen interface—ideal for end users who want easy setup without programming. The **1DC Series** has the controller built-in and connects via EtherNet/IP, PROFINET, EtherCAT, or Modbus/TCP—ideal for OEMs and users who prefer PLC integration. Pricing is similar between the two options.

---

# What is the maximum load capacity of the RLA Series actuators?

URL: https://r2r.tech/resources/faq/what-maximum-load-capacity-rla-series-actuators.md

This question highlights an important distinction that causes confusion: **load weight is not the same as thrust force**.

The RLA Series supports loads up to **30,000 lb on precision linear bearings**. That is the weight sitting on the bearings — the roll, the chuck, the shifting stand structure. The actuator does not lift this weight. It pushes the carriage *sideways* along the bearings, overcoming friction and other resistance forces.

The actual thrust force required to move a 30,000 lb load is typically **120 to 600 lbf**, depending on bearing type, rail condition, and secondary forces like web tension and umbilical drag. The RLA Series provides thrust across three models:

- RLA-050 — 500 lbf thrust
- RLA-100 — 1,000 lbf thrust
- RLA-200 — 2,000 lbf thrust

To illustrate with rough numbers: a 20,000 lb load on profiled linear rails with a friction coefficient of 0.005 (installed, not catalog) produces approximately 100 lbf of friction force. Add inertia, web tension lateral component, umbilical drag, and a factor of safety — and the required thrust might be 250 to 400 lbf. An RLA-050 handles that with margin.

The key takeaway: **do not select an actuator based on load weight alone.** Run the force calculation to determine actual thrust demand. Our [actuator sizing calculator](https://r2r.tech/actuator-sizing-calculator) does exactly this.

Roll-2-Roll Technologies RLA actuators are deployed in hundreds of installations across converting, printing, and packaging lines, reliably guiding loads from a few thousand pounds up to the rated 30,000 lb capacity — many running continuously for years.

---

# What is the purpose of a dead bar in line guiding?

URL: https://r2r.tech/resources/faq/what-purpose-dead-bar-line-guiding.md

### Preventing Loss of Focus

In line or contrast guiding, optical sensors or cameras are used to track a printed feature or line. These sensors require a stable focal distance to operate accurately. However, as the web guide mechanism actuates (moves back and forth), it creates a "twisting" effect in the web span, causing the web plane to shift closer to or further away from the sensor. This movement, known as **pass line variation**, can cause the sensor to lose focus, affecting the amount of light reflected back and disrupting the "teaching" or tracking of the feature.

### Web Stabilization

The dead bar acts as a stabilizer. By wrapping the web over this bar, the web is forced to maintain a fixed distance relative to the sensor, regardless of the guide's movement or the twisting happening in the span. The sensor is then mounted specifically to "look" at the web directly over this dead bar.

### Installation Specifications

- Mounting: The sensor should be installed to view the web while it is in contact with the dead bar.
- Wrap Angle: To prevent the dead bar from influencing the lateral dynamics of the web too heavily (which could cause drag or steering issues), the wrap angle should be kept small.Dead Bar (Stationary): Maximum of 5 degrees wrap.
- Idler/Backup Roller (Rotating): Up to 15 degrees wrap.

### Application in Terminal Guides

For **unwind** or **rewind** applications where line guiding is required, the setup is slightly different to accommodate the moving stands:

- Unwind: A shifting idler or dead bar must move with the unwind stand to support the web, but the sensor must be fixed to the machine frame,.
- Rewind: The sensor moves with the rewind stand (chasing the web), and a fixed idler or dead bar is placed in the span just before the rewind.

---

# What is the resolution of WPS sensors?

URL: https://r2r.tech/resources/faq/what-resolution-wps-sensors.md

WPS (Web Position Sensor) series sensors have a resolution of 0.0635mm with ±0.25mm linearity across the full sensing range. The update rate is 500 Hz, providing fast response for high-speed applications.

---

# What is the widest center guiding range available?

URL: https://r2r.tech/resources/faq/what-widest-center-guiding-range-available.md

Roll-2-Roll offers the widest center guiding capability in the industry. Using two [ODC 960](https://r2r.tech/products/sensors/odc-960) sensors in a dual-sensor configuration provides 1,920 mm (75.6 inches) of total width coverage. This allows center guiding for extremely wide webs or applications with dramatic width variations—all while maintaining 0.127 mm resolution. This is unprecedented in the industry, as traditional systems would require expensive custom solutions or cannot achieve this range at all.

---

# What light source should I use for line/contrast guiding?

URL: https://r2r.tech/resources/faq/what-light-source-should-i-use-linecontrast-guiding.md

Light source selection depends on your application:

- Infrared (880 nm): Best for most high-contrast applications including black lines on white, coating edges, and foil substrates. Works for both edge guiding and line guiding with the same sensor.
- White Light: Required for low-contrast patterns, subtle color differences, and applications where infrared cannot distinguish the feature.
- UV (385 nm): Required when the line is printed with UV-fluorescent ink that is invisible under normal lighting.

Contact Roll-2-Roll Technologies to discuss your specific material and line characteristics.

---

# What line speeds can edge guiding handle?

URL: https://r2r.tech/resources/faq/what-line-speeds-can-edge-guiding-handle.md

R2R edge guiding systems maintain ±0.1mm accuracy at speeds up to 500 meters per minute (1,640 fpm). With a 500 Hz update rate, the sensors respond fast enough for high-speed converting lines.

---

# What load capacity can Roll-2-Roll rewind guides handle?

URL: https://r2r.tech/resources/faq/what-load-capacity-can-roll-2-roll-rewind-guides-handle.md

Roll-2-Roll Technologies electromechanical rewind guides can handle loads up to **30,000 lbs (13,600 kg)** when paired with low-friction linear rail bearings (coefficient ~0.01).

**Key specifications:**

- Maximum thrust: 50–1,500 lbf (222–6,670 N)
- Stroke length: 1–12 in (25–300 mm)
- Maximum speed: Up to 2 in/sec (51 mm/sec)

The critical factor for sizing is **breakaway force**—the static friction the actuator must overcome to start moving the loaded stand. Using low-friction linear rail bearings dramatically reduces the required actuator size compared to sliding shaft designs (coefficient ~0.25).

For extremely heavy loads, the RLA Series ball screw actuators provide thrust up to 1,500 lbf while maintaining precision positioning.

---

# What maintenance is required for Roll-2-Roll electronic Master/Slave systems?

URL: https://r2r.tech/resources/faq/what-maintenance-required-roll-2-roll-electronic-masterslave-systems.md

Roll-2-Roll Technologies electronic Master/Slave guiding eliminates the mechanical components that require constant maintenance in legacy systems:

**Eliminated maintenance items:**

- Motorized sensor positioner motors and drives
- Lead screws and anti-backlash nuts
- Sliding brackets and linear bearings
- Mechanical linkages between Master and Slave positions

**What remains:** Standard periodic inspection of sensors and guides—the same maintenance as any web guiding system, without the additional burden of sensor positioning hardware.

Typical customers report saving 10-20 hours annually in maintenance time previously spent on mechanical positioner systems.

---

# What materials can Roll-2-Roll edge sensors detect?

URL: https://r2r.tech/resources/faq/what-materials-can-roll-2-roll-edge-sensors-detect.md

[Roll-2-Roll® Sensors](https://r2r.tech/products/sensors) use patented fiber-optic technology based on light scattering rather than light blocking. This means they detect the physical presence of the web edge regardless of optical properties.

**Materials that work:**

- Clear and transparent films
- Porous nonwovens
- Metallic foils
- Glass
- Mesh and perforated materials
- Rubber and textiles
- Carbon fiber
- Abrasive materials

The only challenging material is matte carbon black that absorbs infrared light without reflection—and even this can be addressed by angling the light source.

---

# What materials can Roll-2-Roll sensors inspect?

URL: https://r2r.tech/resources/faq/what-materials-can-roll-2-roll-sensors-inspect.md

Roll-2-Roll® sensors work on nearly all web materials, including many that defeat conventional sensors:

- Clear films — PET, BOPP, cellophane, and other transparent materials work without special settings
- Mesh and porous webs — accurately measured where conventional sensors fail
- Metals and foils — aluminum, copper, steel strip
- Textiles and nonwovens
- Glass and carbon fiber

The patented light-scattering and spatial-filtering technology detects edges and features regardless of material opacity or surface finish. **No recalibration is needed when switching between materials.**

One capability is unique to Roll-2-Roll® sensors: **detecting clear film edges under vacuum**. Ultrasonic sensors cannot function without air as a transmission medium, and camera-based systems struggle with transparent materials. Roll-2-Roll® sensors are the only sensing technology that reliably detects clear films in vacuum environments.

The one challenging material is matte carbon black — the solution is to angle the light source perpendicular to the web to increase light scattering at the edge.

---

# What minimum line width can Roll-2-Roll® Sensors detect for guiding purposes?

URL: https://r2r.tech/resources/faq/what-minimum-line-width-can-roll-2-rollr-sensors-detect-guiding-purposes.md

[Roll-2-Roll® Sensors](https://r2r.tech/products/sensors) can detect and track lines with a minimum width of 2 mm (0.08 in). The sensors also support negative space guiding—tracking the gap between printed features (such as the white space between labels) rather than a printed line. This eliminates the need to print a dedicated registration line, saving ink costs and allowing closer trim to printed edges.

---

# What problem occurs when single edge sensors face width changes?

URL: https://r2r.tech/resources/faq/what-problem-occurs-when-single-edge-sensors-face-width-changes.md

- Manual Sensor Respositioning: If the web is guided to the centerline position using single-edge methods, the sensor must be moved for every width change, increasing setup time and complexity. 
- Possible Operator Error: Physical repositioning relies on the operator to correctly locate the sensor relative to the machine and securely lock it in position. Mistakes here can lead to misalignment. 
- Fork Sensor Issues: Conventional fork stype sensors could snag the web material if the sensor is not moved before the width change. And even after width change the sensor needs to be repositioned to ensure that the web is inbetween the two sensing arms. 

Legacy systems attempt to solve this with mechanical sensor positioners (moving sensor center guides or even moving a single sensor), but these introduce additional mechanical wear and tear. [Roll-2-Roll® Sensors](https://r2r.tech/products/sensors) solves this with sensors and adjusting the **electronic guide point** using [Roll-2-Roll® Controller](https://r2r.tech/products/controllers), eliminating the need to physically move the sensor when the web width changes. 

More importantly the [Roll-2-Roll® Sensors](https://r2r.tech/products/sensors) are single sided completely eliminating the possibility of snag or web threading issues during width change over. 

---

# What sensing range do I need for edge guiding?

URL: https://r2r.tech/resources/faq/what-sensing-range-do-i-need-edge-guiding.md

Roll-2-Roll offers sensing ranges from 48 mm to 960 mm (1.9 in to 38 in). For edge guiding, the sensing range should accommodate your maximum expected web wander plus a safety margin. Wider sensing ranges also allow handling multiple web widths without repositioning the sensor—for example, a 960 mm sensor can track webs from narrow labels to wide films without adjustment, eliminating changeover time and operator errors.

---

# What structural requirements must be met for a successful chasing system?

URL: https://r2r.tech/resources/faq/what-structural-requirements-must-be-met-successful-chasing-system.md

Chasing systems move heavy machinery (slitter bases, coating heads) rather than lightweight web rollers. This imposes strict mechanical requirements:

1. Structural rigidity: The carriage must be stiff enough that its natural frequency exceeds the control frequency (typically >25-50Hz). If the sensor bracket wobbles, it creates "false error" and causes oscillation.
2. Breakaway force: The actuator must overcome static friction in the linear bearings. [Roll-2-Roll® Actuators](https://r2r.tech/products/roll-2-roll-actuators) provide up to 2,000 lbf (8,900 N) thrust.
3. Acceleration over speed: The actuator must change direction fast enough to match web error rates. Speed alone won't help if the carriage can't accelerate quickly.

**Rule of thumb:** If the system oscillates or hunts, check carriage rigidity first—it's the most common cause of chasing failures.

---

# When should I use a Roll-2-Roll sensor instead of a full machine vision system?

URL: https://r2r.tech/resources/faq/when-should-i-use-roll-2-roll-sensor-instead-full-machine-vision-system.md

When you need vision-like inspection capabilities but a camera-based machine vision system would be overkill for the application.

Machine vision systems excel at complex pattern recognition and two-dimensional image analysis, but they require programming, calibration, controlled lighting, and a vision expert to deploy and maintain. Roll-2-Roll® sensors fill the gap for applications where **spatial awareness matters but full 2D imaging is unnecessary**:

- Splice detection — identify tape splices, overlaps, and joints in real time
- Flag detection — detect operator flags and registration marks with a 48 mm sensing window (vs. 2–8 mm for conventional mark sensors)
- Tear and void inspection — detect holes, tears, and surface anomalies across the web
- Multi-strip width monitoring — measure multiple strip widths and gaps simultaneously
- Thread counting — count individual threads or strings

Roll-2-Roll® sensors deliver these inspection capabilities with zero programming, zero calibration, and setup in minutes — making them the practical choice when traditional sensors are not enough but a full vision system is more than you need.

---

# When should I use line guiding instead of edge guiding on an unwind application?

URL: https://r2r.tech/resources/faq/when-should-i-use-line-guiding-instead-edge-guiding-unwind-application.md

The choice between edge guiding and line guiding depends on what defines "correct position" for your process:

**Use Edge Guiding When:**

- The physical web edge is your reference (e.g., die-cutting to edge, edge-aligned lamination)
- Material has consistent, clean edges
- Processing unprinted or solid-color materials

**Use Line Guiding When:**

- Processing pre-printed materials where print registration matters more than edge position
- Web edges are inconsistent (ragged, variable width) but printed marks are reliable
- Guiding to a coating edge rather than the substrate edge
- Running materials with printed registration marks or tracking lines

**The Roll-2-Roll Technologies Advantage:** With [ODC 960](https://r2r.tech/products/sensors/odc-960) wide-aperture sensors, you can switch between edge and line guiding modes without changing hardware. This is particularly valuable for slitter rewinder applications that process both plain substrates (edge guide) and pre-printed materials (line guide) on the same machine.

The sensor automatically adapts to detect either the physical edge or a contrast line based on your selection in the [SCU5](https://r2r.tech/products/sensor-controller/scu5) or [SCU6x](https://r2r.tech/products/sensor-controller/scu6x) controller interface.

---

# Where should a sensor be located relative to the web guide?

URL: https://r2r.tech/resources/faq/where-should-sensor-be-located-relative-web-guide.md

### Intermediate Guides (Displacement & Steering Guides)

For web guides located within the machine process, the sensor must be placed in the **exit span** (the web span immediately following the guide roller).

- The "1/3rd Rule": The sensor should be located in the upper 1/3rd (or at least the first half) of the exit span.
- Avoid Delays: Placing the sensor too far downstream or in the next span creates time phase lag (delay). This causes the guide to continue moving even after the error is corrected, leading to system instability and oscillation.
- Steering Guides: The sensor should be placed as close as possible to the exit roller within the exit span.

### Terminal Guides (Unwind & Rewind)

Because terminal guides move the entire roll stand, the sensor mounting acts differently:

- Unwind Guides: The sensor must be fixed to the machine frame (it does not move with the stand). It should be placed immediately downstream of the last shifting idler on the unwind stand.
- Rewind Guides: The sensor must be attached to the moving rewind stand so it moves with the carriage (chasing the web). It should sense the web position just ahead of the last fixed idler using a mechanical arm connected to the rewind stand. Ideally, this is as close to the winder as possible to minimize instability caused by mechanical arm stiffness.

### Plane Change Considerations

If the motion of the web guide causes the web plane to twist or shift significantly (common in line guiding), it can cause focus issues for optical sensors. In these cases, a **backup roller or dead bar** should be installed, and the sensor should be mounted to look at the web directly over this stabilizer to maintain a constant focal distance. 

---

# Why do moving sensor center guides require multiple control loops?

URL: https://r2r.tech/resources/faq/why-do-moving-sensor-center-guides-require-multiple-control-loops.md

Traditional center guiding with mechanical sensor positioners requires two competing control loops: Loop 1 guides the web to the target centerline position, while Loop 2 continuously moves the sensors to chase the web edges as width changes. These loops must be carefully tuned to avoid fighting each other, which can cause hunting behavior and oscillation. Roll-2-Roll systems eliminate this complexity by using wide [Roll-2-Roll® Sensors](https://r2r.tech/products/sensors) that see both edges without moving—only one control loop is needed to maintain centerline, simplifying commissioning and improving stability.

---

# Why do Roll-2-Roll® Sensors not require recalibration between materials?

URL: https://r2r.tech/resources/faq/why-do-roll-2-rollr-sensors-not-require-recalibration-between-materials.md

[Roll-2-Roll® Sensors](https://r2r.tech/products/sensors) use patented fiber-optic technology with adaptive edge detection algorithms. Unlike ultrasonic sensors that measure sound reflection (affected by material density and porosity) or simple infrared sensors that require threshold adjustment,  [rr sesors] use spatial light filtering to detect edges regardless of material properties. The sensor automatically adapts to different reflectivity, transparency, and surface characteristics—whether running clear films, opaque substrates, metallic foils, or porous nonwovens.

---

# Why does Roll-2-Roll use stepper motors instead of servo motors in web guiding actuators?

URL: https://r2r.tech/resources/faq/why-does-roll-2-roll-use-stepper-motors-instead-servo-motors-web-guiding-actuators.md

Let us be direct: servo motors are excellent. They offer smooth torque delivery, high bandwidth, and precise closed-loop control. For many motion control applications, they are the right choice. The question is whether web guiding is one of those applications — and for OEM-shipped actuators, the answer favors steppers for specific, defensible reasons.

**The OEM shipping problem:** Roll-2-Roll Technologies builds actuators that ship to converting, printing, and packaging facilities worldwide. Servo drives require load-dependent tuning — reflected inertia ratio, friction characterization, and mechanical resonance all depend on the *installed* machine, not the actuator alone. A stepper motor sized conservatively at design time requires **no field tuning**. It works out of the box regardless of what it is bolted to.

**The web sensor outer loop:** This is the key enabler. In web guiding, position feedback comes from a [Roll-2-Roll® Sensor](https://r2r.tech/products/sensors) observing the actual web edge — not from an encoder on the motor shaft. Every source of actuator imprecision (lost steps, backlash, drivetrain compliance) is corrected by the sensor on the next correction cycle. The actuator does not need to be a precision positioning device. It needs to move reliably in the commanded direction.

**What we give up — honestly:**

- Efficiency — steppers draw current at rest to hold position; servos draw only what the load demands
- Speed — stepper torque drops off faster at higher speeds than servo torque
- Noise — steppers are audibly louder during motion, especially at certain speeds
- High duty cycle — continuous rapid cycling favors servo thermal characteristics

For web guiding — where corrections are slow (0.5 to 2 Hz), the motor is at rest most of the time, and field simplicity matters — these tradeoffs are acceptable. The result is a reliable, zero-tuning actuator that has performed across hundreds of installations.

---

# Why doesn't standard web guiding work for slitting to a printed line or coating registration?

URL: https://r2r.tech/resources/faq/why-doesnt-standard-web-guiding-work-slitting-printed-line-or-coating-registration.md

Standard web guiding steers the web to a fixed position, but in tool tracking applications like slitting to a printed line, the sensor must see the **relative position** between the tool and the web.



Here's why fixed sensors fail:



1. Fixed sensor upstream: The sensor sees web wander and commands the slitter to move—but it never sees the slitter move. The error signal remains, and the control loop is open.
2. Fixed sensor downstream: By the time you detect misalignment after the slitter, the cut has already happened. You cannot correct a cut that's already made.



The only solution is to mount the sensor **on the moving tool carriage**. When the carriage moves, the sensor moves with it, verifying the correction. This closes the feedback loop and enables true chasing.

---

# Why is a sensor attached to a moving rewind frame?

URL: https://r2r.tech/resources/faq/why-sensor-attached-moving-rewind-frame.md

Unlike other forms of guiding, the goal is to align the *rewind roll* to the position of the incoming *web*, ensuring a straight wound roll.

Specific reasons for this configuration include:

- Chasing Control System: Rewind guiding is fundamentally a "chasing control system" rather than a lateral control system. The rewind stand must physically move to position the winding roll directly downstream of wherever the web happens to be.
- Maintaining Relative Position: If the sensor were fixed to the ground (as it is in unwind guiding), the system would not know the relative position between the winding roll and the incoming web. By attaching the sensor to the moving stand, the sensor moves with the carriage. When the sensor detects the web edge, the controller moves the entire stand (and the attached sensor) until the sensor is re-aligned with the web, effectively "chasing" it to maintain the correct relationship.
- Roll Alignment: This setup ensures that the edge of the rewind roll is constantly aligned with the edge of the approaching web, regardless of where the web is drifting laterally.

Ideally, this sensor should be located just ahead of the last fixed idler in the machine and as close to the winder as possible to minimize instability caused by the mechanical arm's stiffness.

---

# Why is center guiding better than edge guiding for some applications?

URL: https://r2r.tech/resources/faq/why-center-guiding-better-edge-guiding-some-applications.md

Center guiding provides three key advantages: First, it naturally averages out edge defects and fuzzy nonwoven edges, resulting in more stable control. Second, it is immune to wrinkles—when a wrinkle narrows the web, center guiding sees the width reduction on both sides and maintains the true centerline. Third, for symmetric processes like coating or laminating, maintaining the centerline ensures equal margins on both sides. Edge guiding would require the web edge to stay perfectly straight, which is challenging with materials like nonwovens.

---

# Why must Master and Slave sensor web paths be equal distance to the lamination nip?

URL: https://r2r.tech/resources/faq/why-must-master-and-slave-sensor-web-paths-be-equal-distance-lamination-nip.md

In Master/Slave guiding, timing is critical. The Slave guide must correct for a Master web movement at the exact moment that movement reaches the lamination nip.

**The rule:** Web path distance from Master Sensor → Lamination Nip should equal the distance from Slave Sensor → Lamination Nip.

**Why it matters:** If paths are unequal, the Slave might correct too early or too late (phase mismatch), causing misalignment at the actual lamination point.

**The fix:** If physical constraints prevent matching path lengths, [Roll-2-Roll® Controllers](https://r2r.tech/products/controllers) can apply dynamic compensation—electronically delaying the feed-forward signal to match the transport time difference.

---

# Why must the sensor be fixed to the machine frame in unwind guiding?

URL: https://r2r.tech/resources/faq/why-must-sensor-be-fixed-machine-frame-unwind-guiding.md

The "fixed sensor rule" is fundamental to unwind guiding physics and is the **opposite** of rewind chasing:

**The Logic:** In unwind guiding, you are positioning the web to enter the machine at a specific target location. The sensor acts as that target. The controller moves the shifting stand until the web edge aligns with the fixed sensor position.

**The Common Mistake:** If you mount the sensor on the moving stand (as you would in a rewind chasing application), the sensor moves *with* the error. When the stand shifts left, the sensor shifts left too—so from the sensor's perspective, nothing has changed. The system cannot detect or correct the misalignment relative to the machine frame.

**Proper Configuration:**

- Sensor: Fixed to the machine frame (floor or fixed structure)
- At least one idler roller: Mounted on the shifting stand (moves with it)
- Sensor position: Immediately downstream of the shifting idler

This configuration ensures the sensor sees true web position relative to the machine, while the shifting idler maintains a consistent web plane as roll diameter changes.

---

# Why must the sensor move with the rewind stand?

URL: https://r2r.tech/resources/faq/why-must-sensor-move-rewind-stand.md

In rewind chasing applications, the sensor **must be mechanically attached to the shifting stand** because the control system is designed to keep the sensor output at "zero." When the sensor moves with the roll, the system naturally drives the stand until the sensor aligns with the web edge.

If the sensor were fixed to the floor (like in intermediate guiding), the system would lose the relative position between the web and the roll face. The result would be telescoped or uneven rolls because the guide has no reference point for where the roll edge should be.

The sensor should observe the web at a fixed idler immediately upstream of the shifting stand. This provides a stable reference point while the stand—and sensor—move together.

---

# A Fiber Optic Sensor For Web Edge Detection

URL: https://r2r.tech/articles/fiber-optic-sensor-web-edge-detection.md

### Authors



Aravind Seshadri, Prabhakar R. Pagilla



### Publication Information



Conference: The 14th International Symposium on: Smart Structures and Materials & Nondestructive Evaluation and Health Monitoring



### Abstract



A laser based fiber-optic sensor was proposed in our previous work. The sensor developed was based on the principle of scattering of light and the sensitivity directional property of optical fibers. A beam of light is incident on a surface or an edge, the scattered light is received by a linear array of optical fibers. The lateral position of the web edge is determined based on the intensity of light received by each fiber in the fiber array. Static experiments were conducted to show the feasibility of the sensing strategy. In this work, the performance of the sensor is evaluated on an actual web handling platform. The analysis of static and dynamic (with non-zero web transport velocity) experimental data of the sensor under various realistic operating conditions and disturbances is conducted. A direct comparison of the fiber optic sensor and two existing industrial sensors is presented. The experimental data from the sensors are compared using different web materials and under different operating conditions. The new fiber optic sensor is more accurate and the measurements are less noisy. Further, the new sensor overcomes some of the key limitations of existing sensors. The problem of determining the actual position of the web when it is completely outside the sensing window or when it completely covers the sensing windows is resolved; the solution consists of a new configuration. The new configuration also improves the precision of the sensor.



[Link to the Article](http://proceedings.spiedigitallibrary.org/proceeding.aspx?articleid=1301166)

---

# A Hierarchical Optimization Algorithm for Cooperative Vehicle Networks

URL: https://r2r.tech/articles/hierarchical-optimization-algorithm-cooperative-vehicle-networks.md

##### Authors

 Carlo Branca, Rafael Fierro

##### Publication Information

 Conference: American Control Conference, 2006 June 14, 2006, 6 pages

##### Abstract



In this paper, we combine model predictive control (MPC) and mixed integer linear programming (MILP) into a hierarchical optimization framework capable of solving a class of coordination problems in multi-vehicle networks. A critical issue in MPC/MILP applications is that the underlying optimization problem must be solved on-line. This introduces a time constraint that is hard to meet when the number of vehicles and the number of obstacles increase. To alleviate this problem, we implement some heuristics that significantly improve the efficiency of the proposed hierarchical, decentralized optimization scheme. Numerical simulations verify the scalability of the algorithm to the number of vehicles and complexity of the environment.



[Link to the article](http://ieeexplore.ieee.org/xpl/login.jsp?tp=&arnumber=1657382&url=http%3A%2F%2Fieeexplore.ieee.org%2Fxpls%2Fabs_all.jsp%3Farnumber%3D1657382)

---

# A Hierarchical Optimization Approach for Cooperative Vehicle Networks

URL: https://r2r.tech/articles/hierarchical-optimization-approach-cooperative-vehicle-networks.md

### Authors

 Carlo Branca

### Publication Information

 Oklahoma State University Theses, December 2005

### Abstract

 This research presents a control algorithm for the cooperative control of unmanned mobile robots. The algorithm relies on continuously solving an open loop mixed integer linear programming optimization problem. Since the model can become quite complex when the number of robots and the complexity of the environment increase, computational problems can arise. To overcome these problems an approach involving a hierarchical decentralized formulation of the optimization problem is proposed.

[Link to the article](https://shareok.org/handle/11244/10187)

---

# A New Laser-based Sensing System for Monitoring and Control of Webs

URL: https://r2r.tech/articles/new-laser-based-sensing-system-monitoring-and-control-webs.md

### Authors

 AK Abbaraju, PK Peddi-Ravi, A Seshadri, PR Pagilla

### Publication Information

 Conference: Smart Structures and Materials
 March 16, 2006

### Abstract

 A new laser based sensing system for measuring the velocity of the web is proposed in this paper. The doppler shift between the incident light and scattered light from a moving particle contains information about the velocity of the particle. A collimated laser source is incident on the web edge and scattered light is collected. The proposed sensing system measures the true velocity of the web by measuring the doppler shift. The doppler shift is measured by heterodyning the scattered light and incident light. The sensor is capable of measuring the web velocity in all three directions, longitudinal, lateral, and transverse. The measurement of the three true velocity components will be highly beneficial for both monitoring and control of webs. The theory of operation of the sensing system is developed based on the reference beam technique. The methods that will be used for processing various signals are given. The architecture of the sensor is described and construction of the sensing system is underway. The experimental platform developed thus far is discussed in detail.

[Link to the Article](http://proceedings.spiedigitallibrary.org/proceeding.aspx?articleid=1282421)

---

# A New Sensor for Web Flutter Measurement

URL: https://r2r.tech/articles/new-sensor-web-flutter-measurement.md

### Authors

 Aravind Seshadri, Prabhakar R. Pagilla

### Publication Information

 Conference: The 15th International Symposium on: Smart Structures and Materials & Nondestructive Evaluation and Health Monitoring
 March 27, 2003

### Abstract

 A new sensor for web flutter measurement is proposed in this paper. The sensor is based on the principle of scattering of light and directional properties of optical fibers. A collimated beam of light is incident on the web edge and scattered light from the web edge is collected using a linear array of optical fibers. As the web flutters the point of scattering moves. Due to the directional property of the optical fibers, each fiber collects scattered light that is incident on it at certain angles. The motion of the scattering point as the web flutters is directly related to which fibers are being illuminated within the fiber array. The other end of the fiber array is terminated onto a linear array of photodiodes (pixels). Based on which fibers in the array are receiving scattered light and the amount of light received, the transverse displacement (web flutter) of the web can be determined. This paper describes the construction and working of the new sensor for web flutter measurement. Experiments conducted on a web platform show that the sensor is capable of accurately measuring web flutter. The frequency response of the sensor is limited only by the scanning rate of the pixel array and not by the flutter measurement method. A dedicated signal processing circuit can be used to obtain a desired scanning rate, thus, a desired frequency response.

[Link to the Article](http://proceedings.spiedigitallibrary.org/proceeding.aspx?articleid=833033)

---

# A New Web Edge Sensor for Guiding Applications

URL: https://r2r.tech/articles/new-web-edge-sensor-guiding-applications.md

## Why is a web edge sensor important?



To converters, faster speeds, thinner and lighter materials mean more production at less cost. However, these conditions can also mean a higher cost of downtime. Web guiding is one of these important, yet often overlooked aspect of the converting process. The trend for faster speeds and thinner material exposes the limitation of the current web edge sensor technologies; accurately detecting the web edge position for thinner and low basis weight materials are becoming increasingly difficult. This can potentially lead to operational problems such as glue on rollers, misplaced layers of material, material wrinkling or tears which can lead to downtime. Moreover, these problems can also lead to poor quality products with aesthetic problems as well as products that fail quality and regulation standards. All in all, time, money, and products are wasted with inaccurate sensing technology. The new web edge sensor technology eliminates these problems for the nonwoven industry.



## How does the current edge sensor technology perform?



Today’s sensor technology is based on the principle of signal blocking. The blocking principle requires an emitter in one arm and a receiver in the opposite arm. The web runs between the arms and blocks an ultrasonic, pneumatic, or infrared signal. By measuring the magnitude of unblocked signal on the receiver the web position is inferred. This sensing principle provides a inferred measurement that is dependent on the web material properties. 

 ![Blocking principle of U-shaped web edge sensors](https://r2r.tech/r2r-tech/sites/default/files/inline-images/Sensor%20using%20blocking%20principle.JPG)

## Drawbacks of existing web edge sensors



Sensors based on this blocking/unblocking principle work on the assumption that the material is 100% impermeable to the emitted signal. However, materials are often not 100% impermeable, especially nonwovens. This requires calibration of the sensor for each type of material. Furthermore, this type of technology can only infer or guess the position of the material. When the material characteristics change the sensor will perceive a change in the signal but the position of the material is wrongly inferred. Every time the material characteristics change, the sensor has to be recalibrated to a new percentage of impermeability.



## How does the new web edge sensor technology work?



Faster speeds and thinner materials… these are two of the most important trends the nonwoven industry equipment manufacturers are challenged to adapt to. One of the innovative technological developments of 2015 addresses these two trends by providing a major leap in web guiding through [a new web edge or web position sensor technology](https://www.r2r-tech.com/articles/aris-intelligent-sensor) based on the principle of light scattering and a patented fiber optic sensing principle.



## What is the fiber optic sensor's working principle?



[The new sensor technology](https://www.r2r-tech.com/articles/aris-intelligent-sensor) with the light scattering and patented fiber optic sensing principle provides an accurate web edge or web position measurement. The fiber optics act as a spatial filter that allows only the light signal that is in direct line with the fibers. A one-dimensional pixel array collects and converts the filtered light into a digital voltage signal which is processed using an advanced digital signal processing algorithm. Unlike the current sensor technology, the fiber optic sensors have the ability to detect the accurate edge position of any type of material without the need for any manual adjustments of the sensor.

 ![Fiber Optic Sensor - Light Scattering and Spatial Filtering Principle](https://r2r.tech/r2r-tech/sites/default/files/inline-images/Sensor%20using%20light%20scattering%20principle.JPG)

## How is the new web edge sensor technology unique?



An interesting difference between the current technology sensors and the fiber optic sensor is the latter is encased in one arm. This breaks away from the traditional design of U-shaped sensor that requires an arm for signal emission and an opposite arm for signal capture. Fiber optic sensors have the signal emission and reception on the same arm. This compact design reduces damage from impacts in the production line. 



## How is the new web edge sensor's capabilities quantified?



[Extensive testing has proven the capability of the sensor](https://www.youtube.com/watch?v=HS6wYKNfRbo)  with any material without calibration both in static and closed loop setup. Results confirmed the ability of the sensor to accurately detect the material, and in combination with the control algorithm of the guide, correctly position the material under various simulated disturbances. The new sensor technology has a resolution of 0.0635 mm and accuracy of over 99%.



## Conclusion



In general, the new fiber optic sensor technology offers the nonwoven sector an easier transition into higher speeds, handling thinner and lighter materials. Moreover, this sensing technology allows converters to reduce equipment inventory since one sensor can be used for multiple applications where a combination of ultrasonic, infrared and pneumatic sensors might be required.

---

# A Novel Edge Sensor for Web Guiding

URL: https://r2r.tech/articles/novel-edge-sensor-web-guiding.md

### Authors

 Aravind Seshadri, Anil Abbaraju and Prabhakar R. Pagilla

### Publication Information

 Conference: Smart Structures and Materials 2006: Sensors and Smart Structures Technologies for Civil, Mechanical, and Aerospace Systems
 Volume:6174, April 11, 2006

### Abstract

 Existing edge sensors use the concept of blocking/unblocking for measuring web lateral position. The most commonly used sensors employ either ultrasonic or infrared signals to detect the web edge position by measuring the amount of signal attenuation due to blocking/unblocking of the signal. The main drawback of this sensing method is nonuniform signal attenuation due to web material variations and opacity. The research in this paper develops a new sensor which utilizes the phenomena of light scattering from the web edge and the directional sensitivity of optical fibers. A collimated laser beam is incident on the web edge and scattered light is collected by a linear array of fibers spatially positioned above the web edge. The theory of operation and the development of the sensor is described. Experiments are conducted with different web materials to validate the proposed sensing method. A representative sample of the results are presented and discussed.

[Link to the Article](http://proceedings.spiedigitallibrary.org/proceeding.aspx?articleid=1282418)

---

# Accuracy, Precision, Linearity, and Resolution in Web Guiding: Understanding the Terminology

URL: https://r2r.tech/articles/accuracy-precision-linearity-and-resolution-web-guiding-understanding-terminology.md

As we search for the most appropriate equipment for our operation, we are faced with the task of selecting from myriad options based on technical data and specs. Through these data, manufacturers are trying to present the benefits of their products based on the device’s performance profile. However, sometimes what appears to be the best offer, based on what looks to be the best technical data, might not really be the best. The technical data can even be irrelevant information when considering performance. That is the issue with accuracy, precision, linearity and resolution in the web guiding world…



First, we need to be clear of what these terms really mean.Typically, these terms are thrown around as indicators of performance. However, in many instances, these indicators are incorrectly applied or interpreted.



## Accuracy



Accuracy is an indicator of a measurement that is true. Simply put, we are looking at how close is the average of all measurements to the real value of what is measured. So, in average, we are really measuring what we say we are measuring. If we were to use shooting as an example, high accuracy would mean that the average of all shots taken is right at the target, or very close to it. In the case of web guiding, accurate sensing and guiding of material means the average sensing and placement of the material is very close to the true and desired position. However, the spread of individual occasions of the positioning of the material might be so wide that it makes the accuracy useless. In the shooting example, we would have a wide pattern with the average on the target.



## Precision



Precision is an indicator of the consistency of our measurements. In the shooting example, high precision would mean we are constantly hitting the same target. Some would say the grouping is very tight. However, the target we are hitting consistently might be the wrong one! This is a problem faced with sensors that employ a blocking principle in detecting the web. The sensor needs to be calibrated every time there is a material change, otherwise, the sensor will infer the position of the web based on a calibration for a different material characteristic. The measurement will be consistent, but it will not be accurate.



The following images illustrate how accuracy and precision would be represented in the case of hitting a target for the different situations discussed above.

 ![Example illustrating the concept of accuracy and precision](https://r2r.tech/sites/default/files/inline-images/Examples-of-accuracy-and-precision.jpg)

As we can see, a combination of high accuracy and precision is required to guarantee the proper positioning of the material by web guiding systems. Accuracy would allow for the average of all measurements of the web location to be at the true location, and after actuating the guide, the average of all positioning at the desired location. Precision would have each individual measurement very close to the average of the all measurements, and after actuating the guide, each individual positioning of the web very close to the average positioning of the web.



## Linearity



Another term used and presented in technical sheets regarding sensors for web guides is linearity. Linearity is an indicator of the consistency of measurements over the entire range of measurements. In general, it is a good indicator of performance quality of a sensor, but on its own, it can be a misleading indicator. In simple terms, linearity tells us how well the instrument measurement corresponds to reality. In this case we want a linearity as close to 1.0 as possible. A linearity of 1.0 means that if the real position of the material is 1.0 mm to the right, then the measurement instrument reports a displacement of 1.0 mm to the right. If the real position is 2.0 mm to the right, then the measurement instrument should indicate a displacement of 2.0 mm to the right, and so forth. If we traced this relationship in a two-axis graph we should get a straight line with a slope of 1.0.



Sensors with a blocking principle present an interesting case regarding linearity. The sensor can have a linearity very close to 1.0. However, these types of sensors require calibration in order to maintain its 1.0 linearity when the material characteristics change. As you might have noticed in the paragraph above, there is no reference to the true position of the material, only to how much the material is displaced and how well this displacement is recorded or detected. When material properties change, such as in the case of a material change, the linearity of the sensor is affected.



A problem with sensors that employ a blocking principle is they rely on detecting a percentage of the blocked signal to infer the position of the material. When material properties change the percentage of signal blockage by the web also changes. For example, material “A” might be at a desired position when the sensor records a 30% signal blockage. Material “B” might be at that same position when the sensor records a 40% signal blockage. If the sensor has been originally calibrated for material “A” with a 30% blockage, the sensor has to be recalibrated when running material “B” that has a 40% blockage, otherwise the sensor will erroneously consider that the material is at its correct position when it detects a 30% blockage. The linearity may still remain the same and the displacement might be perceived, but the true position of the material will be in the wrong place and the magnitude of displacement measured by the sensor would be incorrect. The way to counter for this error in existing sensors is to recalibrate the sensor to compensate for the change in the material as the only means to support the accuracy.



## Resolution



Resolution is the smallest measurement an instrument can detect or measure. This technical specification is usually included in technical sheets and is sometimes mistaken for an indicator of precision and accuracy. The higher the resolution, the smaller the measurement it can record. In the case of web edge sensors, it would be the smallest measurement the web position sensor can observe or measure. While high resolution is very desirable, it does not guarantee accuracy and precision. Again, resolution on sensors can be material dependent so it might vary with material property changes. For existing sensors with blocking principle, a material that blocks less (light or sound signal) will have a lower resolution than a material that blocks more. Hence porosity and opacity are known to affect the resolution of the sensors, and therefore, its performance. Again, resolution on its own has no meaning when working with material changes if the sensors are not calibrated each time to compensate for the changes in material characteristics.



## The Status Quo



Even though factual precision and accuracy is not typically reported in technical sheets of most web positioning sensors and web guide systems available, these two measurement indicators should be the ones used to determine the efficacy of sensors. As of now, the industry has relied on implied accuracy indicators based on the product of calibrated gains of the components that make up a web guide system. Still, it is an inferred accuracy and precision as it is not based on real physical measurements of the web position and of the sensor readings. Furthermore, the accuracy is dependent on the calibration of the sensor. In second part of this article we will show how accuracy, precision, resolution and linearity can be quantified for web position sensors as well as web guiding system.



## Conclusion



The question that must be asked is, does my operation require high performance web sensor and guiding capacity? For operations running at lower speeds and with wider tolerances in their web positioning, the answer is probably no. These operations can get by with not having to worry about calibration of their sensors when running different materials. However, operations that run at faster speeds requiring precise placement of the material, calibration will be a must if they are using sensors that operate under a blocking principle. Of course the trade off is lost production time in calibrating sensors, but it is the only way that an adequate accuracy and precision can be achieved. Certainly, misplacement at higher speed will turn into greater amount of wasted materials, and important losses in uptime. There is definitely a need for systems that are not only accurate and precise, but also that eliminate the need for calibration of the web guiding systems to reduce downtime.

---

# Adaptive Control of Web Guides

URL: https://r2r.tech/articles/adaptive-control-web-guides.md

### Authors



Aravind Seshadri and Prabhakar R. Pagilla



### Publication Information



Control Engineering Practice
 Volume 20, Issue 12, December 2012, Pages 1353–1365



### Abstract



Web guides are mechanisms that are used in roll-to-roll material processing machines to control the lateral position of the material while it is transported over rollers in processing machinery; the flexible, continuous materials are often referred to in the industry as “webs”. The process of controlling the lateral position of webs on rollers is referred to as “web guiding”. With the increasing need to transport and process different types of materials under different operating conditions within the same processing machinery, the existing fixed gain control algorithms do not provide adequate performance under these changing conditions and must be re-tuned often to provide satisfactory guiding performance. A controller that will adapt to parameter changes resulting from changes in the material properties, operating conditions, and size and type of guide mechanisms is desired. This paper discusses the design and implementation of model-based adaptive control strategies for web guides based on the dynamic models which describe the lateral behavior of webs. Extensive experiments are conducted for the designed adaptive control strategies for two types of web guides, namely remotely pivoted guide and offset pivot guide. Practical implementation issues and methods to increase robustness of the adaptive strategies are discussed. Experimental results from the adaptive control strategies will be compared with the existing fixed gain PI controller.



[Adaptive Control of Web Guides](http://www.sciencedirect.com/science/article/pii/S0967066112001529)

---

# Adaptive Feedforward Based Control Strategy for Attenuation of Periodic Tension Oscillations in Roll-to-Roll Manufacturing

URL: https://r2r.tech/articles/adaptive-feedforward-based-control-strategy-attenuation-periodic-tension-oscillations-roll.md

### Authors

 Carlo Branca, Prabhakar Pagilla, Karl Reid

### Publication Information

 Process of the Twelfth International Conference on Web Handling June 2013

### Abstract

 Periodic oscillations in the tension signal are frequently observed in roll-to-roll manufacturing due to the presence of many rotating elements which are often non-ideal, such as out-of-round material or eccentric rolls. In certain situations the amplitude of the oscillations is large enough to affect normal operation of the web line. The proportional-integral-derivative (PID) feedback control algorithms that are commonly used for tension regulation do not have the dynamic complexity to compensate for such periodic disturbances. In this paper we investigate a two-degree-of-freedom controller which has two control actions, feedback and feedforward. The feedforward part is adaptive and is designed to provide control actions to compensate for periodic oscillations. Several issues must be considered when designing a control algorithm for the attenuation of periodic oscillations. First, since the control algorithm is executed in real-time using a real-time system which may have restrictions on the sampling period, the complexity of the algorithm must be such that the control action can be computed in a time period that is less than the sampling period, and the sampling period for most systems is typically in the range of tens of milliseconds. Second, it is desirable to have a feedforward algorithm that can be implemented in parallel with an existing feedback control scheme for tension and speed regulation without the need to retune and redesign the existing scheme. Further, it is desirable to have an algorithm that is understandable to practicing engineers who may have limited or no advanced controls background other than an undergraduate course in control systems. Considering the aforementioned issues, an adaptive feedforward (AFF) algorithm that can work in parallel to an existing feedback control systems is developed for control of web tension and to attenuate periodic oscillations. The essential ingredient of the AFF algorithm is the estimation of amplitude and phase of the periodic oscillations based on which a feedforward compensating control action is generated. The action of the AFF algorithm is such that retuning or redesign of the existing feedback controller is not required. Several different configurations of the AFF for different scenarios in terms of where to apply the feedforward action in the control system are investigated. Extensive experiments are conducted on a large web platform with different scenarios and by transporting two different web materials at various speeds. Results from these experiments are presented and discussed. Experimental results show the effectiveness of the proposed AFF algorithm to attenuate tension oscillations.

---

# Analysis and Minimization of Interaction in Decentralized Control Systems With Application to Roll-to-Roll Manufacturing

URL: https://r2r.tech/articles/analysis-and-minimization-interaction-decentralized-control-systems-application-roll-roll.md

### Authors

 Aravind Seshadri, Pramod R Raul and Prabhakar R. Pagilla

### Publication Information

 Control Systems Technology, IEEE Transactions Volume 22, Issue 2, March 2014, Pages 520-530

### Abstract



Analysis and minimization of interaction in multivariable systems employing decentralized controllers with application to roll-to-roll manufacturing systems are considered in this paper. A new interaction metric based on the Perron-Frobenius theory of nonnegative matrices is presented. This new metric may be used to quantify interaction in a large-scale interconnected system, establish constraints on closed-loop system stability, and provide a systematic design procedure for constructing decentralized pre-filters, which minimize interaction. The new interaction metric is applied to a roll-to-roll (R2R) manufacturing system, which utilizes decentralized control systems. R2R manufacturing is a continuous process in which flexible materials are transported on rollers through processing machinery where operations, such as printing, coating, lamination, etc., are performed to obtain finished products. Based on the Perron root interaction metric (PRIM), a comprehensive experimental study to analyze and minimize interaction on a large experimental R2R platform is presented. A representative sample of experimental results which demonstrate the applicability of PRIM is presented and discussed.



[Link to the article](https://scholar.google.com/citations?view_op=view_citation&hl=en&user=Do-3IFsAAAAJ&citation_for_view=Do-3IFsAAAAJ:W7OEmFMy1HYC)

---

# Decentralized Control of Print Registration in Roll-to-Roll Printing Presses

URL: https://r2r.tech/articles/decentralized-control-print-registration-roll-roll-printing-presses.md

### Authors



Aravind Seshadri ; Prabhakar R. Pagilla



### Publication Information



Conference: ASME 2013 Dynamic Systems and Control Conference
 Volume: 1, October 21, 2013



### Abstract



Roll-to-roll (R2R) manufacturing is a type of continuous manufacturing process extensively used to produce a wide variety of consumer products, such as plastics, paper, films, non-wovens, textile, etc. Recent advances in nanotechnology and material science have enabled the possibility of manufacturing electronics on a flexible substrate using R2R printing techniques. Even though the feasibility of printing electronics on flexible substrates has been extensively studied, continuous printing on a moving substrate using R2R techniques has not been adequately investigated. To facilitate progress towards high precision R2R printing, a systematic investigation of the various aspects that affect print quality and ways in which those can be influenced by different control configurations facilitated by choice and location of various components of the print section is necessary. In this paper we investigate two common control configurations for R2R printing based on the structure of the R2R print section and various components available for control. For these two configurations we develop a state-space model that contains both state and input delays. We propose a decentralized, memoryless, state feedback control law for both control configurations and show the stability of the closed loop systems using frequency domain delay-dependent stability conditions. These control configurations are evaluated and compared using model simulations and discussions on the effectiveness of each strategy are provided.



[Link to the Article](http://proceedings.asmedigitalcollection.asme.org/proceeding.aspx?articleid=1841164)

---

# Design and Development of a New Edge Sensor for Web Guiding

URL: https://r2r.tech/articles/design-and-development-new-edge-sensor-web-guiding.md

### Authors



Aravind Seshadri and Prabhakar R. Pagilla



### Publication Information



Sensors Journal, IEEE
 Volume:7 , Issue: 5, May 2007, Pages 698 - 706



### Abstract



Existing edge sensors use the concept of blocking/unblocking to determine web lateral position. The most commonly used sensors employ either ultrasonic or optical signals to detect the web edge position by measuring the amount of signal attenuation due to blocking/unblocking of the signal. The main drawback of this sensing method is nonuniform signal attenuation due to web material variations and opacity. The research in this paper develops a new sensor which utilizes the phenomena of light scattering from the web edge and the directional sensitivity of optical fibers to determine the web lateral position. A collimated light beam is incident on the web edge and scattered light is collected by a linear array of fibers spatially positioned above the web edge. Based on the intensity of light received by each fiber in the fiber array, lateral position of the web is determined. The theory of operation and the development of the sensor is described. Experiments are conducted with different web materials to validate the proposed sensing method. A representative sample of the results are presented and discussed. 



[Link to the Article](http://ieeexplore.ieee.org/xpl/login.jsp?tp=&arnumber=4154694&url=http%3A%2F%2Fieeexplore.ieee.org%2Fxpls%2Fabs_all.jsp%3Farnumber%3D4154694)

---

# Design of Delay Independent State Feedback Control for Roll-to-Roll Printing Applications

URL: https://r2r.tech/articles/design-delay-independent-state-feedback-control-roll-roll-printing-applications.md

### Authors

 Aravind Seshadri, Prabhakar R. Pagilla and Jamie E. Lynch

### Publication Information

 Conference: ASME 2014 Dynamic Systems and Control Conference
 Volume 3, October 22, 2014

### Abstract

 Control of print quality (registration) in roll-to-roll (R2R) printing is challenging because of the presence of transport delays involved in the printing process. In this work we present a delay-independent state feedback control design to stabilize a R2R printing press by considering all the significant dynamics involved in the printing process. State feedback control design using past state measurements (controllers with memory) are discussed first. Since controllers with memory are less desirable in industrial applications, we investigate and discuss the feasibility of designing a simple, memoryless, delay-independent state feedback controller for printing applications. The feasibility is shown by the use of a control design procedure that exploits the structure information in the system matrix to find a stabilizing controller. The design procedure is also extended to other common industrial R2R control strategies, such as decentralized control and state feedback with integral action for R2R printing applications.

[Link to the Article](http://proceedings.asmedigitalcollection.asme.org/proceeding.aspx?articleid=2086238)

---

# Fiber optic web edge sensor 

URL: https://r2r.tech/articles/fiber-optic-web-edge-sensor.md

### Authors

 Prabhakar Pagilla, Aravind Seshadri

### Publication Information

 US Patent: US8324604
 Priority date: Nov 9, 2006
 Publication date: Dec 4, 2012

### Abstract

 A web edge sensor is disclosed. The web edge sensor has a light source directing light incident to an edge of a web. The edge of the web scatters the light and a sensor array that detects a first portion of the light scattered from the edge of the web and rejects a second portion to determine a position of the web edge.

[Link to the article](https://www.google.com/patents/US8324604)

---

# Fiber-Optic Sensor for Web Velocity Measurement

URL: https://r2r.tech/articles/fiber-optic-sensor-web-velocity-measurement.md

### Authors

 Aravind Seshadri, Pranav-Kumar Peddi-Ravi, Prabhakar R Pagilla

### Publication Information

 Sensors Journal, IEEE
 Volume: 8 , Issue: 7, July 2008, Pages 1099-1104

### Abstract

 The design and development of a new fiber-optic sensor for measuring the velocity of a continuous material (also called a web) in material processing systems is described. The development of the proposed sensor is based on the dual beam laser Doppler velocimetry technique and the unique properties of different types of optical fibers. The developed sensor is capable of measuring the true web transport velocity as opposed to the existing methods which infer web transport velocity based on the roller angular speed. Since the sensor design utilizes fibers, signal processing can be performed away from the measurement area, and as a result the sensor can be used in harsh environments within the web processing line. The proposed sensor has been constructed and experiments have been conducted on an experimental web platform. The performance of the sensor is evaluated for a range of web velocities and different web materials. Sensor design, its construction, and a representative sample of the results are presented and discussed.

[Link to the Article](http://ieeexplore.ieee.org/xpl/login.jsp?tp=&arnumber=4567497&url=http%3A%2F%2Fieeexplore.ieee.org%2Fxpls%2Fabs_all.jsp%3Farnumber%3D4567497)

---

# Fighting the Fear of Change and Innovation

URL: https://r2r.tech/articles/fighting-fear-change-and-innovation.md

Does your company have a fear of change?



Our previous articles mention how to include innovation in a company’s [management](https://r2r.tech/articles/innovation-company-culture-or-go-word-part-2) and [culture.](https://r2r.tech/articles/innovation-manufacturing-company-culture-or-go-word) But what if it’s more basic than that? What if fear of change is holding your company back from meeting its full potential? Time and money play a large role in what management might be willing to spend to go to the next level. If fear is getting in the way, it will slow progress even more. According to the article on Conquering Enemies of Innovation posted on [Harvard Business Review](https://hbr.org/2012/12/conquering-the-enemies-of-inno), fear is the top inhibitor to innovation.



> Fear of innovation and change is holding your company back.



Thirty percent say they fear making mistakes, making it the top barrier to innovation due to fear. Second is getting fired or appearing less dedicated. Other factors inhibiting innovation include, fear of dealing with difficult customers or clients, conflict with managers, speaking in front of a group and disagreements with coworkers.



With odds like that, it’s no wonder there is serious lack of innovation within our companies or industry. So what can we do?



1. Trust.  It is key in opening the door of communication. It seems that it applies to everything aside from communication, and it's true. Lack of communication can lead to lack of innovation, and trust might be an issue that impedes good communication. Instead of killing the messenger, we need to be open and inviting to new ideas. Communication requires trust. Trust that their ideas will be listened to instead of immediately shot down, and trust that they won’t be in trouble if the idea fails.
2. Get Organized.  Break down the task into smaller and more doable chunks. At each step, whether it’s success or failure, you learn something. If you succeed, it boosts your confidence and you can apply the same thinking later on. If you fail, it’s a lot easier to analyze that step, figure out what you did wrong, rather than do everything at once and not know where you went wrong.
3. Encourage experimentation. An environment to cultivates fear probably doesn’t encourage positive learning experiences or experiments. If encouraged to take risks, there is no limit to what a group of individuals can accomplish together. Some of the best inventions were made by learning from mistakes.
4. Cultivate Talent.  Some people are born with exceptional talent, but that is the exception not the rule. Most people have to work on fine tuning their natural abilities until progressively getting better at said skill. Having a management team that is willing to invest in building up its employees will see immeasurable benefits in the long run, especially when it comes to bringing in new innovative practices.
5. Change Your Perspective. It’s not failure if you learned something, right? So, ask yourself these three questions:  What did I learn from this situation?
6. How can I grow as a person from this experience?
7. What can I do differently next time



Even Thomas Edison failed, but he kept learning and made one of the biggest breakthroughs of all time. Not only did he give us light, but people are constantly using his story as motivation not to give up. You might never succeed how you think you should, but with a slight tweaking of perspective, then maybe you can accomplish something you never even thought of. Check out our other information on how to lead an innovative company and how to bring innovative culture to your company.

---

# Governing Equations for Web Tension and Web Velocity in the Presence of Nonideal Rollers

URL: https://r2r.tech/articles/governing-equations-web-tension-and-web-velocity-presence-nonideal-rollers.md

### Authors

 Carlo Branca, Prabhakar R Pagilla, Karl N Reid

### Publication Information

 Journal of Dynamic Systems, Measurement, and Control Volume 135, Issue 1, January 2013,

### Abstract

 Since rotating machinery is used to transport flexible materials (commonly known as webs) on rollers, it is common to observe periodic oscillations in measured signals such as web tension and web transport velocity. These periodic oscillations are more prevalent in the presence of nonideal elements such as eccentric rollers and out-of-round material rolls. One of the critical needs in efficient transport of webs is to maintain web tension at a prescribed value. Tension regulation affects almost all key processes involved during web transport including printing, registration, lamination, winding, etc. Governing equations for web tension and transport velocity that can accurately predict measured behavior in the presence of nonideal rollers are beneficial in understanding web transport behavior under various dynamic conditions and the design of suitable web tension and speed control systems. The focus of this paper is on modeling the effect of eccentric rollers and out-of-round material rolls on web tension and web transport velocity. The new governing equations for web velocity on an eccentric roller and web tension in spans adjacent to the eccentric roller are presented and discussed; a web span is the free web between two consecutive rollers. To solve these governing equations, the location of the entry and exit point of the web on the eccentric roller as it rotates and the length of the web spans adjacent to the eccentric roller are required; a procedure for obtaining this information is described. To corroborate the models and the developed approach, data from experiments on a large experimental web platform are compared with data from model simulations, and a representative sample of the results are presented and discussed.

[Link to the article](http://dynamicsystems.asmedigitalcollection.asme.org/article.aspx?articleid=1656788)

---

# Hedging Point Policies for Multi State Failure Prone Manufacturing Systems

URL: https://r2r.tech/articles/hedging-point-policies-multi-state-failure-prone-manufacturing-systems.md

##### Authors

 Carlo Branca and Francesco Martinelli

##### Publication Information

 Decision and Control, 2003. Proceedings. 42nd IEEE Conference Volume 3, December 9, 2012, Page 2150-2155

##### Abstract



In this paper we consider a single-product single-machine manufacturing system, with the machine characterized by multiple working modes. A cost is associated both with inventory surplus and demand backlog and the policy which minimizes the overall long-run expected cost, which based on previous work in literature is known to be a multiple hedging point policy, is analyzed. This paper derives a condition on system parameters for the optimality of just-in-time (JIT) policies and investigates the dependence of hedging points on the ratio among inventory surplus and backlog cost parameters. Some numerical examples are included to illustrate the effectiveness of the achieved results.



[Link to the article](http://ieeexplore.ieee.org/xpl/login.jsp?tp=&arnumber=1272936&url=http%3A%2F%2Fieeexplore.ieee.org%2Fxpls%2Fabs_all.jsp%3Farnumber%3D1272936)

---

# Hierarchical Optimization Strategies for Deployment of Mobile Robots

URL: https://r2r.tech/articles/hierarchical-optimization-strategies-deployment-mobile-robots.md

### Authors

 Carlo Branca, Rafael Fierro

### Publication Information

 International Journal of Intelligent Control and Systems (IJICS), Special Issue on Swarm Robotics Volume 11, Issue 3, 2006, Pages 141-153

### Abstract



In this paper, we integrate model predictive control (MPC) and mixed integer linear programming (MILP) into a hierarchical framework suitable for solving optimization problems involving robotic networks. A critical issue in MPC/MILP applications is that the underlying optimization problem must be solved on-line. This creates a time constraint which is hard to meet when the number of robots and the number of obstacles increase. To alleviate this difficulty, we develop strategies that significantly improve the efficiency of a hierarchical, decentralized optimization scheme. As an application is considered a case of target assignment problem in urban-like environments. Numerical simulations verify the scalability of the algorithm to the number of robots and complexity of the environment.



[Link to the Article](http://citeseerx.ist.psu.edu/viewdoc/download?doi=10.1.1.471.9895&rep=rep1&type=pdf)

---

# How to Size an Actuator for Unwind and Rewind Web Guides

URL: https://r2r.tech/articles/how-to-size-an-actuator-for-unwind-and-rewind-web-guides.md

## Introduction

This is Part 2 of our series on unwind and rewind web guides. In [Part 1](https://r2r.tech/articles/unwind-and-rewind-guides-design-and-installation-considerations), we covered the design and installation of the guide frame — the shifting stand, linear bearings, and mechanical layout. Now we turn to the actuator: the component that converts electrical energy into the precise linear motion needed to position the web.

We manufacture the [RLA Series actuators](https://r2r.tech/products/web-guide-actuators) specifically for terminal web guiding applications, so we have a direct interest in helping you size them correctly. But the force model presented here is universal. You can use it to size any linear actuator — hydraulic, pneumatic, or electric — for any shifting-stand web guide. We would rather you size the job correctly and choose a competitor's product than undersize one of ours and have it fail in your mill.

What follows is our engineering methodology for determining the minimum thrust required to move a loaded roll stand reliably. We will build the force model from first principles, account for the real-world forces that simplified models often omit, and work through a realistic example with numbers you would actually encounter on a converting or paper line.

---

## The Complete Force Model

Most actuator sizing guides present a clean two-term equation: friction plus inertia. That model is correct in a classroom, but it is incomplete for an installed web guide. Experienced web handling engineers know that the real force budget includes several additional terms that can individually exceed the friction force.

We will build the model in layers, starting with the textbook terms and then adding the forces that show up on the plant floor.

### The Full Force Equation

$$F_{total} = F_{friction} + F_{inertia} + F_{tension} + F_{umbilical} + F_{grade} + F_{misalignment}$$

Where:

| Term | What It Represents |
| ---- | ------------------ |
| $F_{friction}$ | Rolling or sliding friction of the linear bearing system |
| $F_{inertia}$ | Force required to accelerate the total moving mass |
| $F_{tension}$ | Lateral force from web tension acting through the steering angle |
| $F_{umbilical}$ | Drag from cables, hoses, and conduit that flex as the stand moves |
| $F_{grade}$ | Gravitational component if the floor is not perfectly level |
| $F_{misalignment}$ | Additional resistance from real-world installation tolerances |

After computing the comprehensive total, we apply a true safety factor for genuine unknowns:

$$F_{required} = F_{total} \times FoS$$

This is an important distinction. The safety factor should account for unknowns the model cannot capture — transient shock loads, degradation over time, contamination — not compensate for forces we failed to model. By accounting for all known forces explicitly, we can use a more rational FoS rather than inflating it to cover model deficiencies.

---

### Term 1: Bearing Friction — $F_{friction}$

$$F_{friction} = \mu \cdot m_{total} \cdot g$$

Where:
- $m_{total}$ — combined mass of the full roll and the shifting stand (kg)
- $\mu$ — coefficient of friction for the bearing system
- $g$ — gravitational acceleration, 9.81 m/s²

**Catalog Friction Coefficients**

| Bearing / Guide Type | Catalog $\mu$ | Notes |
| -------------------- | ------------- | ----- |
| Profile linear rail (recirculating ball) | 0.003–0.005 | Most common in modern guide frames |
| Circular linear bearing (round shaft) | 0.004–0.006 | Round shaft guides |
| Cam rollers on machined steel plate | 0.002–0.005 | Common in legacy guide frames |
| Needle roller bearings | 0.004–0.005 | Track rollers, cam followers |
| Precision roller bearings | ~0.0018 | High-precision applications |
| Plain bushing / bronze sleeve | 0.07–0.12 | Legacy equipment, high friction |

For profile linear rails — the most common bearing type in modern shifting stands — catalog friction is very low. On a 13,000 lb (5,897 kg) stand, $F_{friction}$ at $\mu = 0.004$ computes to only 52 lbf (231 N). That number is correct for a clean, perfectly aligned rail in a catalog. It is not necessarily what you will see on the plant floor, which is why Term 6 (misalignment) exists.

---

### Term 2: Inertia — $F_{inertia}$

$$F_{inertia} = m_{total} \cdot a$$

Where:
- $a$ — desired linear acceleration of the stand (m/s²)

Web guiding does not require high acceleration. Typical correction speeds are 0.25–1.0 in/s (6–25 mm/s), and the stand accelerates over 50–200 ms. A reasonable design acceleration for most terminal guides is 1–3 in/s² (0.025–0.076 m/s²).

Even at these modest rates, inertia can dominate the bearing friction term when the load is heavy. At 2 in/s² (0.051 m/s²) with a 13,000 lb total load, $F_{inertia}$ is approximately 67 lbf (300 N) — already larger than the friction term for profile linear rails.

---

### Term 3: Web Tension Lateral Force — $F_{tension}$

This is the force most commonly omitted from simplified sizing models, and it can be the largest single term in the equation.

When a web guide steers the stand, the guide roller deflects the web at a small angle. The web, under tension, pulls back laterally. The lateral force is proportional to the web tension and the sine of the steering angle:

$$F_{tension} = 2 \cdot T_{web} \cdot \sin(\alpha)$$

Where:
- $T_{web}$ — total web tension (lbf or N)
- $\alpha$ — steering angle at the guide roller (radians or degrees)
- The factor of 2 accounts for the web entering and leaving the guide roller

The steering angle $\alpha$ is typically small in web guiding — often 0.5° to 2°. But web tensions can be substantial. Consider a paper mill running 4 PLI on a 120-inch web:

- $T_{web}$ = 4 PLI × 120 in = 480 lbf
- $\alpha$ = 1° (0.0175 rad)
- $F_{tension}$ = 2 × 480 × sin(1°) = 2 × 480 × 0.01745 = 16.8 lbf

At 2° steering angle, that doubles to approximately 33.5 lbf. On a high-tension process — steel, foil lamination, or heavy board — web tensions of 1,000–3,000 lbf are common, and the lateral force scales proportionally.

For converting applications with lighter webs (film, nonwoven), this term may be only 5–15 lbf. For paper and board at moderate tensions, expect 15–60 lbf. For metal foil and high-tension processes, this term can reach 50–150 lbf or more.

**Important:** This is a sustained force, not transient. The actuator must overcome it continuously during any active correction, not just during acceleration.

---

### Term 4: Umbilical and Cable Drag — $F_{umbilical}$

Every shifting stand has connections that move with it: electrical cables for sensors and drives, pneumatic or hydraulic hoses for brakes or tension systems, grease lines, signal conduit. These umbilicals resist motion through bending stiffness, friction where they slide or hang, and inertia of the cables themselves.

There is no clean formula for this force because it depends entirely on the installation — how many hoses, what diameter, how they are routed, whether they are in a cable carrier or draped freely. In practice:

| Installation Complexity | Typical $F_{umbilical}$ |
| ----------------------- | ----------------------- |
| Light — a few signal cables, cable carrier | 5–15 lbf (22–67 N) |
| Moderate — signal cables plus 1–2 pneumatic hoses | 15–30 lbf (67–133 N) |
| Heavy — hydraulic lines, multiple hoses, rigid conduit | 30–60 lbf (133–267 N) |

If you cannot measure the umbilical drag directly (a spring scale pull test on the disconnected stand is the most reliable method), use 20–50 lbf as a reasonable estimate for a typical converting or paper line with moderate hose connections. This term is often underestimated.

---

### Term 5: Floor Slope — $F_{grade}$

Mill floors are not flat. Settling, construction tolerances, and intentional drainage grades mean the stand's travel axis may be on a slight slope. The gravitational force component along the travel direction is:

$$F_{grade} = m_{total} \cdot g \cdot \sin(\theta)$$

Where:
- $\theta$ — angle of the floor slope along the travel axis

This force is constant and directional — it helps motion in one direction and opposes it in the other. The actuator must be sized for the opposing direction.

How large is this in practice? A 0.5° slope — barely perceptible to the eye — on a 13,000 lb load:

$$F_{grade} = 5{,}897 \times 9.81 \times \sin(0.5°) = 5{,}897 \times 9.81 \times 0.00873 = 505\text{ N} \approx 113\text{ lbf}$$

That single term exceeds the combined friction and inertia forces from the textbook model. If your mill floor has even a minor grade along the actuator's stroke axis, you must account for it.

For most installations, measure the slope with a precision level. If measurement is impractical, assume 0.25°–0.5° as a conservative estimate.

---

### Term 6: Misalignment and Binding — $F_{misalignment}$

This is the term that separates textbook calculations from field reality. Catalog friction coefficients assume perfect rail alignment, proper preload, clean surfaces, and correct mounting torque. Installed systems have:

- Rail parallelism errors from shimming and floor irregularities
- Carriage preload changes from bolting to an imperfect subframe
- Contamination from paper dust, oil mist, metal fines
- Thermal effects causing differential expansion

Industry experience — widely documented in linear motion engineering references — is that installed friction is typically **2 to 5 times** catalog values for well-maintained systems, and can reach **10 times** catalog values for poorly maintained or contaminated installations.

Rather than trying to model these effects individually, the practical approach is to apply an installation multiplier $k_{install}$ to the bearing friction term:

$$F_{misalignment} = (\,k_{install} - 1\,) \cdot F_{friction}$$

Where $k_{install}$ ranges from:

| Installation Quality | $k_{install}$ |
| -------------------- | ------------- |
| Excellent — precision-ground subframe, clean environment, maintained | 2–3 |
| Typical — structural steel subframe, moderate contamination | 3–5 |
| Poor — legacy frame, heavy contamination, no maintenance program | 5–10 |

This formulation keeps the misalignment force proportional to the load (heavier loads have more rail deflection and more sensitivity to alignment errors) while acknowledging that it is an estimate. If in doubt, use $k_{install}$ = 3 for a new installation with reasonable alignment practices.

**Practical note:** A spring-scale pull test on the actual stand, loaded with a representative roll, will give you a measured friction force that inherently includes the misalignment term. If you can perform this test, it is always preferable to calculation.

---

### Applying the Safety Factor

With all known forces modeled explicitly, the factor of safety can serve its intended purpose: providing margin for true unknowns.

$$F_{required} = F_{total} \times FoS$$

With a comprehensive force model, a FoS of **1.5** is reasonable for well-characterized installations. Use **2.0** if significant uncertainty remains — for example, if you estimated multiple terms rather than measuring them, or if the operating environment is harsh.

| Situation | Recommended FoS |
| --------- | --------------- |
| All forces measured or well-characterized | 1.25–1.5 |
| Some forces estimated, clean environment | 1.5–2.0 |
| Multiple estimates, harsh/contaminated environment | 2.0–2.5 |

Compare this to the common practice of using a simplified (two-term) model with FoS of 3–5. Both approaches can arrive at the same required force — but the comprehensive model tells you *why* you need it, which makes troubleshooting easier if the actuator struggles in service.

---

## From Motor Torque to Linear Thrust

The RLA actuators use a reverse-parallel belt-and-ballscrew mechanism: a toothed belt connects the motor to the ballscrew through a pulley reduction, and the ballscrew converts rotary motion to linear thrust.

The thrust conversion factor:

$$k = R_{belt} \cdot \frac{2\pi}{L} \cdot \eta$$

$$F_{thrust} = T_{motor} \cdot k$$

Where:
- $R_{belt}$ — belt/pulley reduction ratio
- $L$ — ballscrew lead (m)
- $\eta$ — ballscrew mechanical efficiency (approximately 0.90 for rolled ballscrews)
- $T_{motor}$ — available motor torque at operating speed (N·m)

Linear speed:

$$v_{linear} = \frac{n_{motor}}{R_{belt}} \cdot L$$

### A Note on Belt Drive Compliance

The belt-and-ballscrew architecture is a design tradeoff we chose deliberately. The belt reduction allows a smaller, lower-cost motor to deliver high thrust from a compact package — the RLA-200 produces 2,000 lbf from a frame only 111 mm square. A direct-drive motor coupled to a ballscrew without a belt would eliminate the compliance (slight elasticity) the belt introduces, but would require a significantly larger motor and housing for the same thrust.

For web guiding, this tradeoff is favorable. Web guiding corrections are slow (typically under 1 in/s) and do not require the zero-backlash stiffness of a CNC axis. The belt's compliance is well within the tolerance of the control loop. If your application requires nanometer-level positioning or extremely high dynamic stiffness — uncommon in web guiding — a direct-drive actuator may be more appropriate.

---

## The Speed-Torque Relationship

Stepper motors and BLDC motors share a characteristic: torque decreases as speed increases, primarily due to back-EMF reducing the effective voltage driving current through the windings.

At low speeds, the motor delivers its maximum torque. As speed increases beyond a threshold that depends on supply voltage and winding inductance, torque falls. The actual deliverable thrust at any operating speed is:

$$F_{actual}(v) = T_{motor}(n) \cdot k$$

Where $T_{motor}(n)$ is the motor torque at the speed $n$ corresponding to the desired linear velocity.

The RLA actuators use stepper motors with intelligent microstepping drivers that optimize current delivery across the speed range. This extends the usable torque curve compared to basic constant-voltage drivers, but the fundamental speed-torque tradeoff still applies.

**What this means for sizing:** The rated thrust values in the comparison table below are continuous-duty values at rated speed. The actuator can produce higher thrust at lower speeds, and lower thrust at higher speeds. Our [actuator sizing calculator](https://r2r.tech/resources/actuator-sizing-calculator) applies the full speed-thrust curve for the specific model and operating conditions. The methodology in this article gives you the force-side analysis; the calculator handles the actuator-side verification.

---

## Continuous vs. Peak Ratings and Thermal Limits

Actuator thrust ratings are not all defined the same way across manufacturers. For the RLA Series:

- Rated thrust is the continuous-duty thrust the actuator can sustain indefinitely at rated speed without exceeding the motor's thermal limits (typically 80°C winding temperature rise at 40°C ambient).
- Peak thrust — available at low speeds and low duty cycles — can be 1.5–2× the rated value, but thermal limits restrict the duration.

Web guiding is inherently a low-duty-cycle application. The actuator moves only when the web wanders, and corrections are typically small, brief motions separated by dwell periods. This thermal profile is favorable for electric actuators because the motor has time to dissipate heat between corrections. However, during initial roll threading or during a sustained disturbance (roll eccentricity, for example), the actuator may run continuously for an extended period. Size for continuous thrust to ensure reliability in these sustained-demand scenarios.

---

## Competing Approaches — Where Electric Actuators Fit

Electric ballscrew actuators are not the only option for moving a shifting stand. Understanding the alternatives helps you choose the right tool for the job.

**Hydraulic cylinders** are common on very heavy stands (30,000+ lb) where thrust requirements exceed what a compact electric actuator can deliver. They provide extremely high force density and are robust in dirty environments. The tradeoffs are hydraulic infrastructure (pump, reservoir, filtration, piping), potential for leaks near the web, and the need for proportional valves and closed-loop control hardware to achieve the positioning precision web guiding requires.

**Pneumatic cylinders** are sometimes used on lighter stands. They are simple and inexpensive but difficult to control precisely — air is compressible, so achieving smooth, proportional positioning requires proportional valves and often secondary feedback. They are generally not suitable for precision web guiding.

**Direct-drive electric actuators** (motor coupled directly to the ballscrew without a belt or gearbox) offer the highest stiffness and zero backlash. The tradeoff is size: achieving 1,000+ lbf thrust without a reduction stage requires a large, high-torque motor and a correspondingly large actuator body. These are excellent where stiffness is paramount and space is available.

The RLA Series occupies a specific niche: high thrust in a compact frame, purpose-built for the speed and precision demands of web guiding, where the belt-drive compliance is well within tolerance and the compact packaging matters for integration with standard shifting stands.

---

## Worked Example: Paper Mill Unwind Stand

Let us size an actuator for a realistic installation using the complete force model.

**Given:**

| Parameter | Value |
| --------- | ----- |
| Maximum roll weight | 10,000 lb (4,536 kg) |
| Shifting stand weight | 3,000 lb (1,361 kg) |
| Total moving mass ($m_{total}$) | 13,000 lb (5,897 kg) |
| Bearing type | Profile linear rail, $\mu$ = 0.004 catalog |
| Web width | 120 inches |
| Web tension | 4 PLI (480 lbf total) |
| Maximum steering angle | 1.5° |
| Desired correction speed | 0.5 in/s (12.7 mm/s) |
| Desired acceleration | 2 in/s² (0.051 m/s²) |
| Umbilical complexity | Moderate (signal cables + 2 pneumatic hoses) |
| Floor slope (measured) | 0.3° along travel axis |
| Installation quality | Typical ($k_{install}$ = 3) |

---

**Step 1 — Bearing Friction (catalog)**

$$F_{friction} = \mu \cdot m_{total} \cdot g = 0.004 \times 5{,}897 \times 9.81 = 231\text{ N} = 52\text{ lbf}$$

**Step 2 — Inertia**

$$F_{inertia} = m_{total} \cdot a = 5{,}897 \times 0.051 = 301\text{ N} = 68\text{ lbf}$$

**Step 3 — Web Tension Lateral Force**

$$F_{tension} = 2 \cdot T_{web} \cdot \sin(\alpha) = 2 \times 480 \times \sin(1.5°) = 2 \times 480 \times 0.02618 = 25.1\text{ lbf} = 112\text{ N}$$

**Step 4 — Umbilical Drag (estimated)**

$$F_{umbilical} \approx 25\text{ lbf} = 111\text{ N}$$

Based on moderate hose configuration — two 3/8" pneumatic hoses plus signal cables in a cable carrier.

**Step 5 — Floor Grade**

$$F_{grade} = m_{total} \cdot g \cdot \sin(\theta) = 5{,}897 \times 9.81 \times \sin(0.3°) = 5{,}897 \times 9.81 \times 0.00524 = 303\text{ N} = 68\text{ lbf}$$

**Step 6 — Misalignment**

$$F_{misalignment} = (k_{install} - 1) \times F_{friction} = (3 - 1) \times 231 = 462\text{ N} = 104\text{ lbf}$$

---

**Step 7 — Total Force**

| Force Component | lbf | N | Percentage |
| --------------- | --- | --- | ---------- |
| Bearing friction (catalog) | 52 | 231 | 12.8% |
| Inertia | 68 | 301 | 16.7% |
| Web tension lateral | 25 | 112 | 6.2% |
| Umbilical drag | 25 | 111 | 6.2% |
| Floor grade | 68 | 303 | 16.7% |
| Misalignment | 104 | 462 | 25.6% |
| Subtotal ($F_{total}$) | 342 | 1,520 | — |

Note what the complete model reveals: the two textbook terms (friction + inertia) account for only **120 lbf** — barely a third of the actual force budget. The "hidden" forces — misalignment, floor grade, umbilical drag, and web tension — contribute the remaining 222 lbf. This is why simplified models require inflated safety factors.

**Step 8 — Apply Safety Factor**

Because the floor slope was measured and the installation quality is reasonably characterized, but the umbilical drag is estimated:

$$F_{required} = F_{total} \times FoS = 1{,}520 \times 1.75 = 2{,}660\text{ N} = 598\text{ lbf}$$

---

**Step 9 — Select Actuator**

| Candidate | Rated Thrust | Margin over $F_{required}$ | Speed at Rated Thrust |
| --------- | ------------ | -------------------------- | --------------------- |
| RLA-050 | 500 lbf | Insufficient (−16%) | 1.3 in/s |
| RLA-100 | 1,000 lbf | +67% | 1.3 in/s |
| RLA-200 | 2,000 lbf | +234% | 1.1 in/s |

The RLA-100 at 1,000 lbf continuous thrust provides 67% margin above the calculated requirement. This is a comfortable margin that accommodates degradation over time and occasional worst-case conditions.

Notice what happened: a simplified two-term model with FoS = 2.0 would have computed $F_{required}$ = 240 lbf and suggested the RLA-050 at 500 lbf with "76% margin." The complete model shows the actual requirement is 598 lbf — which **exceeds** the RLA-050's rating. The simplified model would have led to an undersized actuator. This is a real failure mode we have seen in the field.

---

## RLA Series Model Comparison

| Specification | RLA-050-xxxx-TG | RLA-100-xxxx-TG | RLA-200-xxxx-TG |
| ------------- | --------------- | --------------- | --------------- |
| Rated thrust (continuous) | 500 lbf (2,224 N) | 1,000 lbf (4,448 N) | 2,000 lbf (8,896 N) |
| Rod diameter | 32 mm | 40 mm | 60 mm |
| Frame cross-section | 60 × 64 mm | 75 × 75 mm | 111 × 111 mm |
| Available strokes | 4", 6", 12" | 4", 6", 12" | 4", 6", 12" |
| Maximum speed | 1.3 in/s | 1.3 in/s | 1.1 in/s |
| Supply voltage | 24/48 VDC | 24/48 VDC | 24/48 VDC |
| Drive architecture | Ballscrew + belt reduction, intelligent microstepping driver with sensorless stall detection |  |  |
| Mounting options | Pivot, rod eye, clevis |  |  |
| Designed for | Roll-2-Roll Technologies shifting stands and SCU6x web guide controllers |  |  |

**Rated thrust values are continuous-duty** at rated speed and 40°C ambient. Peak thrust at low speed and low duty cycle can be 1.5–2× higher. Speed at full rated thrust — see the [sizing calculator](https://r2r.tech/resources/actuator-sizing-calculator) for the complete speed-thrust curve for each model.

---

## Practical Sizing Recommendations

**Measure whenever possible.** A spring-scale pull test on the loaded stand — with all umbilicals connected and the web threaded — gives you $F_{friction} + F_{misalignment} + F_{umbilical}$ in a single measurement. This collapses three estimated terms into one measured value and dramatically improves confidence in the calculation.

**Do not neglect floor grade.** A precision level on the rail surface takes five minutes and can reveal the single largest force in the system.

**Web tension lateral force scales with tension, not web weight.** A light film under high tension generates more lateral force than a heavy paper web under low tension. Always check this term.

**Size for the worst case.** Maximum roll weight, maximum tension, moving uphill (if applicable). The actuator should handle the hardest correction, not the average one.

**Use the sizing calculator for actuator-side verification.** This article gives you the methodology to determine the force your installation requires. The [actuator sizing calculator](https://r2r.tech/resources/actuator-sizing-calculator) maps that force against the specific RLA model's speed-thrust curve, thermal capacity, and stroke length to confirm the selection.

---

## Summary

Sizing an actuator for a shifting-stand web guide requires accounting for six categories of force: bearing friction, inertia, web tension lateral load, umbilical drag, floor grade, and installation misalignment. Simplified two-term models systematically underestimate the real-world force budget and compensate through inflated safety factors that obscure the actual engineering.

The complete model presented here will not give you a single, tidy number. Real installations have uncertainty in several terms. But by modeling every known force explicitly and reserving the safety factor for genuine unknowns, you arrive at a selection you can defend — and troubleshoot if something is not right.

If you have questions about sizing an RLA actuator for your application, or if your force calculation falls between models, [contact our engineering team](https://r2r.tech/contact). We are happy to review your specific installation parameters.

---

# Innovation in Manufacturing : Company Culture or a Go-To Word?

URL: https://r2r.tech/articles/innovation-manufacturing-company-culture-or-go-word.md

Innovation. This word is prominent in most industrial websites, a go-to word in nearly every company description. Yet, [94 percent of managers are displeased with their companies innovation record.](https://hbr.org/2015/04/the-5-requirements-of-a-truly-innovative-company)



> Innovation is more than a go-to word. It's a culture.



If that’s the case, why are so many companies resistant to change? How can we bridge the gap between their expectations and reality?



Unfortunately, even, if they have a steady source of innovative ideas, they are not likely to be implemented. If that’s the case in your business, you’re better off tackling the sources of resistance than using more time brainstorming. It is becoming more and more difficult for organizations to introduce innovative products or services. With budgets tight, managers are looking for rapid return on investment, but they have less money and time to invest, even if new products will save them time and money in the long run.



Getting bogged down in day to day tasks makes innovation nearly impossible and creates tunnel vision. Managers focus on the current need at hand, not on the future of the company. In many cases the solution to their problem is presented to them by an innovative technology, or by an off-the-wall idea. But, we are too busy working hard to dedicate time and evaluate this innovation opportunity..



One problem that executives and managers face when dealing with innovation is that in many cases they don’t even understand what innovation is. Leaders of organizations have to first define innovation and what it looks like to their individual company. A simple product and/or service upgrade is not innovation. A product or service that has developed through incremental advances of its technology or that is new and disruptive can be considered an innovation. Next, the task is to identify metrics that help us evaluate the path required to implement the innovation. These aren’t the only steps of course, but they are the first steps.



## 1. A sharp, shared definition of innovation



In order to have a system in place to cultivate innovation, we have to be sure we know what innovation would look like in our environment. The most difficult part of creating a definition of innovation for our organization is a cultural implementation exercise. As organizational leaders, we want to implement a culture of innovation. As mentioned before, we want to make sure that everyone in the organization can differentiate between a meer product upgrade and true innovation. To help you with your definition, go back over the history of your company to find the true innovations or what you consider game changers and also those that gave a noticeable change in sales. What did those products have in common and how did they change the lives of your customers?



## 2. Comprehensive innovation metrics



You have a definition of innovation, so, how do you measure it? The difficulty arises if you have no historical references within your organization of products or services that evolved or caused disruption in the industry and presented great benefits to your customers. However, there are some metrics that can be employed to help you improve your innovation endeavor by setting goals:



- Investments: How much time, money or resources do you need to make it go?
- Throughput: What is the number and quality of ideas that enter the pipeline? How long does it take for those ideas to move from concept to reality?
- Results: How many of the ideas that enter the pipeline actually make it to the market? How much of the company’s revenue is from these new products and services? And how much does that compare to the time, money and resources spent on it’s development?
- Leadership: How much time is spent mentoring projects and other techniques to promote behaviors conducive to innovation.
- Competence: the percentage of employees who have been trained as business innovators? Has this training lead to higher quality ideas?
- Climate: Is the work for your employees conducive to innovation? Do you have more upsets than progress in the pipeline? What are you doing to remove those upsets?
- Efficiency: changes over time in the ratio of innovation outputs to inputs.
- Balance: the mix of different types of innovation (product, service, pricing, distribution, operations, etc.); differ­ent risk cate­go­ries (incremental improvements versus speculative ventures); and differ­ent time horizons. Once you have these metrics in place, you can set a goal for innovation growth within the company.



Check out the other two articles in this series about [how to cultivate innovation in your management](https://r2r.tech/articles/innovation-manufacturing-company-culture-or-go-word) and [how to conquer your fear of innovation](https://r2r.tech/articles/fighting-fear-change-and-innovation).

---

# Innovation: Company Culture or Go-To Word (Part 2)

URL: https://r2r.tech/articles/innovation-company-culture-or-go-word-part-2.md

Innovation. This word is plastered over every website, a go-to word in nearly every company description, yet, [94 percent of managers are displeased with their companies innovation record.](https://hbr.org/2015/04/the-5-requirements-of-a-truly-innovative-company) [Our previous post](https://r2r.tech/articles/fighting-fear-change-and-innovation) mentioned how to develop innovation into a company culture and [how to conquer your fear of innovation](https://r2r.tech/articles/fighting-fear-change-and-innovation) . But there is still the issue of management. If management doesn’t follow through with innovative developments, even if the rest of the company does, the company will still fail to be innovative.



> Innovation is more than a go-to word. It's your leaders.



Unfortunately, it is becoming more and more difficult for organizations to introduce innovative products or services. As budgets tighten, managers seek rapid returns on investment and fail to look at long term rewards. This is why products that may save them time and money in the long run, and even in the shortrun get overlooked.



Getting bogged down in the day to day task makes innovation nearly impossible, but keeping these next 3 items in focus, you can bring innovation back to your company.



1. ## Employees who’ve been taught to think like innovators.

  Nothing will get better unless you invest time and effort into your employees for systemati­c improvement of the innovation skills of your employees. Most people are not naturally blessed with skills, they are taught and nurtured to cultivate those skills. Individuals who have been trained or given opportunities to practice innovative thinking can work to foster great ideas.  Much has been written about where innovation comes from and what distinguishes an innovative mind. Our research and experience suggest that inquiry is at the heart of it. Innovators have an inclination and a capacity to examine what others often leave unexamined.  So if you want innovation, individuals must to be taught to do four things:  Challenge the status quo. Don’t think about what is, but what could be.
2. Look at the big picture. Don’t think about what is changing, but what could change.
3. Mix and Match. Don’t focus on what you do, focus on what you have. See your organization as a portfolio of skills and assets that can be mix and matched in any number of ways to get new product and businesses.
4. Find solutions. Sometimes customers don’t know they have a problem until there is a solution. They’re used to a certain struggle, but is it a necessary one or are we wasting time and creating new frustrations.
5. ## Accountable and capable innovation leaders

  Who is accountable for innovation in your company? The president, vice president or designated project managers? Does the promotion or lack of innovation affect their compensation? Too often innovation is the responsibility of specialized units like R&D or corporate business development, rather than being the responsibility of every leader at every level. But do they have the training to be a leader in innovation? These qualities include:  Able to use innovation tools available.
6. Accepting sky as the limit for new ideas.
7. Evaluating new options without predetermined judgement.
8. Recognizing innovators and celebrating “smart failures.”
9. Stepping up to mentor innovation teams.
10. Finding ways to free up time and money for innovation.
11. Hiring and promoting for creativity.
12. Eliminating upsets in the innovation pipeline.
13. Finding affordable ways to prototype and experiment.
14. ## Innovation-friendly management processes

 No matter how innovation-focused your employees are, nothing will succeed unless you have a management as committed to innovation as you are. If you have too much dedication in one as such as funding, but don’t have a team with the skills or the commitment to innovation then you won’t get far. The same is true if it’s reversed. One simply can’t work without the other and they have to work together.



The only answer is get every management position on board to take a systematic approach to each area. Make not to see what needs to be worked on and how it can better work with areas within the innovation framework.

---

# Interaction Analysis of Control Systems Employed in Roll-to-Roll Printing

URL: https://r2r.tech/articles/interaction-analysis-control-systems-employed-roll-roll-printing.md

### Authors



Aravind Seshadri and Prabhakar R. Pagilla



### Publication Information



Conference: American Control Conference
 Volume:1, June 17, 2013, Pages 4251-4256



### Abstract



Roll-to-roll (R2R) machines have been extensively used to manufacture a wide variety of consumer products, such as paper, plastics, textile, etc. R2R machines facilitate continuous processing of materials with minimal stoppage time and provide significant improvement in productivity over batch manufacturing. With recent advances in technology it is now possible to manufacture flexible electronics, flexible digital displays, solar films, etc., using R2R processing. R2R processing of flexible electronics requires better understanding of machine and process dynamics to achieve tight tolerances required in their manufacturing. One of the conventional R2R processes that is critical to enable R2R processing of flexible electronics is printing. In this paper, machine and process dynamics for R2R printing are studied in detail. Specifically two control configurations, depending on the type of control input, are analyzed; a compensator based registration control strategy (CRC) typically used with mechanical line shafts (MLS) and a print cylinder angular position based registration control (PARC) strategy used typically with electronic line shafts (ELS), are compared. A comparison of these strategies is given based on a dynamic model for the print section, which includes governing equations for strain in the material, print cylinder velocities, and registration error (a metric that quantifies print quality). An interaction metric is used to analyze interaction of key process variables between print units. Model simulations are conducted for different scenarios to evaluate the strategies. Results of the model simulations are presented and discussed.



[Link to the Article](http://ieeexplore.ieee.org/xpl/login.jsp?tp=&arnumber=6580493)

---

# Interaction in Decentralized Control Systems: Application to Roll-to-Roll Systems

URL: https://r2r.tech/articles/interaction-decentralized-control-systems-application-roll-roll-systems.md

### Authors

 Aravind Seshadri, Pramod R Raul, Prabhakar R Pagilla

### Publication Information

 Conference: ASME 2012 5th Annual Dynamic Systems and Control Conference joint with the JSME 2012 11th Motion and Vibration Conference
 October 1, 2012, Pages 459-466

### Abstract

 A procedure to analyze interaction in an experimental roll-to-roll system that uses a decentralized control strategy is presented in this paper. A Perron root based interaction metric is employed for the analysis. Experiments conducted on a roll-to-roll system are used to evaluate the interaction between different subsystems of the roll-to-roll system. To minimize interaction between subsystems of the roll-to-roll system, a procedure for designing pre-filters based on the Perron root of the system is also discussed in the paper. Experimental results with and without pre-filter clearly indicate the effectiveness of the pre-filter in minimizing interaction. Discussions regarding the roll-to-roll application, stability considerations and insights on using the Perron root based interaction measure for decentralized control applications are also given.

[Link to the Article](http://proceedings.asmedigitalcollection.asme.org/proceeding.aspx?articleid=1739142)

---

# Market Conditions and Anticipated Pricing Changes for 2022

URL: https://r2r.tech/articles/market-conditions-and-anticipated-pricing-changes-2022.md

## We are really grateful for our customers who support us by purchasing our products.



2020 and 2021 have been tough for all but we are really appreciative of the confidence and trust our customers place on us everyday. We are seeing high demand for our products, especially those high end products that provide significant value for our customers. Fortunately we have been able to deliver them with minimal delays. We are blessed to be in this position and we look forward to another record year in 2022.



## What we have done in 2021?



During the past year we have seen unprecedented changes to the whole ecosystem of our supply chain that has significantly affected our ability to deliver products on time for our customers. Fortunately, we have been able to meet the high demand with lead times that are 4 to 6 weeks rather than 10 to 12 weeks that others are experiencing. However, this comes at a cost. High demand across the board and supply chain shortages are creating price increases and longer lead times. We have been able to anticipate and shoulder some of the increases this year, but as we look into 2022 we would have to adjust our prices to provide the same quality of products at the same exceptional level of service.



## What is going to happen in 2022?



We are in the process of finalizing the actual percentage increase in price for our products. We anticipate an average increase of 4% across all our products, some might be higher than others depending on the origin of the components used in the products. The price increase is going to go into effect next year for any orders placed after December 31, 2021. 



## What can you do to get ahead of the price change?



Since we were unable to provide a 90 days prior notice for this price increase, we are allowing customers to place an order this year (before 12/31/2021) but take delivery 120 days after the order date. If you have the ability to plan ahead please take advantage of this option to save some money. 



We strongly believe that our products provide a significantly higher value proposition for their price; our pricing is competitive with current market rates from our peers and competitors. Rest assured that we are also investing in R&D to further increase the value proposition of our products with newer and better offerings. More news about that coming in 2022.



## Thank you for the continued support



We really appreciate your business and trust in us. And we look forward to providing you with quality products, exceptional service at an affordable price.

---

# Method for adaptive guiding of webs

URL: https://r2r.tech/articles/method-adaptive-guiding-webs.md

### Authors



Prabhakar Pagilla, Aravind Seshadri, et al



### Publication Information



US Patent: US8554354
 Priority date: Feb 12, 2010
 Publication date: Oct 8, 2013



### Abstract



A method of adaptive guiding of a web on a roller is disclosed. The method includes computing an output of a reference model, reading an output of a sensor that indicates a web position, determining a difference between the output of the reference model and the output of the sensor, and updating a set off controller parameters for the roller based on the difference.



[Link to the patent](http://www.google.com/patents/US8554354)

---

# Model Reference Adaptive Control of Web Guide

URL: https://r2r.tech/articles/model-reference-adaptive-control-web-guide.md

### Authors

 Aravind Seshadri

### Publication Information

 OSU Theses

### Abstract

 The term web is used to describe materials which are typically manufactured in a roll-to-roll manner. A wide variety of materials such as textile, paper, plastics, composites and metals are manufactured in rolled form because roll-to-roll manufacture of materials is convenient for transport and storage, saves time and reduces costs. As the web is transported in the processing machinery, inherent machine misalignment and process induced disturbance cause lateral fluctuations. These lateral fluctuations, if not controlled, can result in inferior quality of the finished product. The primary focus of this research is on the development and implementation of adaptive control strategies for controlling the lateral fluctuations (lateral control or lateral guiding) in a web processing line. New performance measures which can better assist machine operators in diagnosing lateral behavior were also investigated. A novel model reference adaptive controller, which is referred to as the ``Guide Adaptive Controller'' (GAC), was developed for web guiding applications. The GAC was implemented on an experimental web line and the performance of the controller was compared with an existing industrial controller. The adaptive control strategy resulted in better performance compared to an industrial controller especially when used with difference web materials with opacity and gage variations. Compared to the existing industrial controller, the adaptive controller does not require re-tuning when the operating conditions change because the GAC adapts to process variations and attenuates disturbances. Additionally, the same adaptive controller can be used with different guide mechanisms. Two simplified approximations of GAC were also developed and implemented on an experimental web line in order to observe the adaptive behavior of the controllers. Based on these observations a systematic procedure for industrial implementation of the adaptive control strategy was developed. Extensive experimental results on commercial guides with different operating conditions and disturbances indicate that GAC can provide improved guiding performance when compared to an existing industrial controller. Therefore, GAC has a high potential to successfully replace existing guide controllers. A novel performance metric which provides a better characterization of the guiding performance when compared to existing metrics was developed. The developed metric is based on histograms. Commonly observed histograms were studied and their occurrence in web guiding applications were analyzed. The performance metric can be used as a diagnostic tool in the web processing industry to monitor the occurrence of different machine and process induced disturbances, and also to compare controllers.

[Link to the Article](https://test.shareok.org/handle/11244/10055)

---

# Modeling and Analysis of a Rotating Turret Winder in Roll-to-Roll Manufacturing Systems

URL: https://r2r.tech/articles/modeling-and-analysis-rotating-turret-winder-roll-roll-manufacturing-systems.md

### Authors

 Aravind Seshadri and Prabhakar R. Pagilla

### Publication Information

 Conference: American Control Conference (ACC) June 17, 2013, Pages: 6667-6672

### Abstract

 The process of manufacturing products using roll-to-roll (R2R) methods involves unwinding of thin, flexible material in rolled form into machinery for processing and winding of the processed material into a roll. This paper describes modeling and control of a rotating turret winder in the rewind section of a R2R printing press. Governing equations for web speed and web tension within the rewind section are described by taking into consideration the motion of the rotating turret winder. Data from production runs of an industrial R2R printing press are analyzed to determine web behavior during a wound roll change sequence accomplished by the rotating turret. Model simulations are conducted and data from these simulations are compared with typical data from production runs. The key challenges associated with controlling web speed and web tension in a rewind section containing a rotating turret winder are discussed along with recommendations for machine and control design to achieve improved regulation of process parameters.

[Link to the article](http://ieeexplore.ieee.org/xpl/login.jsp?tp=&arnumber=6580886&url=http%3A%2F%2Fieeexplore.ieee.org%2Fxpls%2Fabs_all.jsp%3Farnumber%3D6580886)

---

# Modeling and Control of a Rotating Turret Winder Used in Roll-to-Roll Manufacturing

URL: https://r2r.tech/articles/modeling-and-control-rotating-turret-winder-used-roll-roll-manufacturing.md

### Authors



Aravind Seshadri, Prabhakar R. Pagilla



### Publication Information



Control Engineering Practice
 Volume: 41, August 2015, Pages 164–175



### Abstract



In this paper, winding issues in an industrial R2R printing press using a rotating turret winder are investigated by utilizing a new mathematical model and data are collected during production runs. Production data and simulation results from the developed model are analyzed to identify the causes for tension disturbances that affect winding quality. Model simulations are conducted by incorporating production data as inputs to the model to gather insights into the effect of dynamic behavior of the rotating turret winder on winding web tension. The developed model captures the various dynamic events associated with the roll change operation with a rotating turret winder. Measured data are provided to support the results of this work in improving winding tension regulation during the roll change operation. The new model together with the analysis and recommendations provides a good framework for the development of model-based tension control schemes that can further improve winding tension regulation performance, and thereby improves wound roll quality.



[Link to the Article](http://www.sciencedirect.com/science/article/pii/S0967066115000751)

---

# Modeling and Control of Web Transport in the Presence of Non-Ideal Rollers

URL: https://r2r.tech/articles/modeling-and-control-web-transport-presence-non-ideal-rollers.md

### Authors



Carlo Branca



### Publication Information



Oklahoma State University Dissertation, May 2013



### Abstract



In roll-to-roll processes the presence of non-ideal elements, such us out-of-round or eccentric rollers is fairly common. Periodic oscillations in web tension and web velocity are observed because of the presence of such non-ideal elements. Models of web transport on rollers based on the ideal behavior of various machine elements are not able to reproduce these oscillations in model simulations but can only follow the average of the measured tension and velocity signals. In order to reproduce the tension oscillations the models have to be modified to include the mechanism that creates the oscillations.



The first part of this dissertation discusses the necessary modification of the governing equations of web velocity and web tension in the presence of an eccentric roller and an out-of-round roll. It was found that two aspects need to be included in the model: (i) the web span length adjacent to the non-ideal roller is varying with time and must be included in the governing equation for web span tension and (ii) the material flow rate in the web span, which is needed for deriving the governing equation for web tension, is not proportional to the peripheral velocity of the roller as in the ideal case and must be explicitly computed. An extensive set of experiments is presented to validate the proposed governing equations for web transport.



The second part of the dissertation addresses the problem of designing a control algorithm for the attenuation of oscillations in the presence of a non-ideal roller. Besides stability, the controller needs to guarantee robustness to changing configurations and simplicity for real time implementation. An adaptive feed-forward control algorithm is identified as a suitable control algorithm for the attenuation of tension and velocity oscillations. The algorithm estimates amplitude and phase of the oscillations and generates a control input which compensates for the oscillations. Extensive experiments are conducted on a large web platform with different scenarios and by transporting two different web materials at various speeds. Experimental results show the effectiveness of the proposed algorithm to attenuate tension and velocity oscillations due to non-ideal rollers.



[Link to the article](https://shareok.org/handle/11244/10959)

---

# Modeling Print Registration in Roll-to-Roll Printing Presses

URL: https://r2r.tech/articles/modeling-print-registration-roll-roll-printing-presses.md

### Authors



Aravind Seshadri, Prabhakar R. Pagilla and Jamie E. Lynch



### Publication Information



Journal of Dynamic Systems, Measurement, and Control
 Volume:135 , Issue: 3, May 2013, 11 Pages



### Abstract



Roll-to-roll (R2R) printing is a continuous process in which thin flexible materials such as paper are passed through a printing press to print the required pattern onto the material. Each printing press may have several printing units depending on the number of colors to be printed and the complexity of the pattern. The flexible material, often referred to as a “web,” is passed successively through each print unit to create a multicolor pattern. Print registration is the process of overlapping successive printed patterns to form a complex multicolor pattern and the registration error is the position misalignment in the overlapped patterns. This paper develops a machine direction print registration model in a printing press with multiple print units whose print cylinders are driven using mechanical line shafts. The registration model considers the effects of interaction between adjacent print units due to variations in material strain and machine dynamics, including various dynamic elements, such as the print cylinder, doctor blade assembly, print unit compensator roller, print unit motor, friction at various locations, etc. Measured data from typical production runs on an industrial printing press are used to corroborate the developed print registration model. Mechanical design and control design recommendations to reduce registration error in print units are also provided. The developed registration model is applicable to many R2R printing technologies, such as offset, flexo, and rotogravure printing.



[Link to the Article](http://dynamicsystems.asmedigitalcollection.asme.org/article.aspx?articleid=1674712)

---

# Modeling, Analysis and Control of Print Registration in Roll-to-Roll Printing Presses

URL: https://r2r.tech/articles/modeling-analysis-and-control-print-registration-roll-roll-printing-presses.md

### Authors

 Aravind Seshadri

### Publication Information

 OSU, 2013, 168 Pages

### Abstract

 Print registration in roll-to-roll (R2R) printing process is investigated in this dissertation. Print registration is the process of aligning multiple images that are printed in consecutive print units. The quality of the print output depends on the proper alignment of these images. A new mathematical model for print registration is developed by considering the effect of key process variables, such as web tension and transport velocity, print cylinder angular position and velocity, and the compensator roller position. Sources of machine induced disturbances and their effect on print registration are also investigated and machine design recommendations to mitigate these disturbances are given. Propagation of disturbances between print units due to web transport is investigated. The interaction, or the disturbance propagation behavior, between print units is studied by developing a new interaction metric called the Perron Root based Interaction Metric (PRIM). The new interaction metric, for large-scale interconnected systems employing decentralized controllers, is developed using tools from the Perron-Frobenius theory. A systematic procedure to minimize interaction is given by designing pre-filters for decentralized control systems. The disturbance propagation behavior with two registration control strategies is compared using the PRIM and it is found that a compensator based registration control (CRC) has smaller magnitude of disturbance propagation when compared to a print cylinder angular position based registration control (PARC). It is also found that a simple, decentralized, memoryless, state feedback controllers stabilizes print units with CRC. Results from a number of model simulations and experiments are provided to support the recommendations and conclusions.

[Link to the article](http://gradworks.umi.com/35/88/3588486.html)

---

# New Web Edge Sensor Technology for Web Guiding

URL: https://r2r.tech/articles/new-web-edge-sensor-technology-web-guiding.md

Faster speeds and thinner materials… these are two of the most important trends the nonwoven industry is experiencing and equipment manufacturers are challenged to adapt to these trends rapidly. One of the innovative technological developments of 2015 addresses these two trends by providing a major leap in web guiding through [the new sensor technology](https://r2r.tech/documentation/material-agnostic-fiber-optic-web-edge-sensor) based on the principle of light scattering and a patented fiber optic sensing principle.

 ![Fiber optic web edge sensor for web guiding applications](https://r2r.tech/sites/default/files/inline-images/Next%20Generation%20of%20Web%20Edge%20Sensing%20Technology_0.jpg)

To the converter, faster speeds, thinner and lighter materials mean more production at less cost. However, these conditions can also mean a higher cost of downtime, as the number of units that could have been produced is higher, and of precision in material control of the web, as any deviation from the required accuracy will translate into more defective products.



Web guiding is one of these important, yet often overlooked, material control components. The trend for faster speeds and thinner material exposes the limitation of the current sensor technology in precisely detecting the true position of the web material.



At the end, what this translates to the converter in the nonwoven industry is operational problems such as glue on rollers, misplaced layers of material, material wrinkling or tears, and manual adjustments of the sensor due to changes in material thickness and density, product aesthetic problems such as misplaced resealable closures, and health issues such as glue or other materials that come into contact with the skin of the infant.



All in all, time, money, and products are wasted with inaccurate sensing technology. The new technology eliminates these problems for the nonwoven industry.



Today’s sensor technology is based on the principle of signal blocking. The blocking principle requires an emitter in one arm and a receiver in the opposite arm. The web runs between the arms and blocks an ultrasonic, pneumatic, or infrared signal. They provide a relative, inferred, analog measurement.



Sensor systems based on this principle depend on the assumption that the material is 100% impermeable to the emitted signal. However, materials are often not 100% impermeable, especially nonwovens, and this requires calibration of the sensor for each type of material. Furthermore, this type of technology can only infer or guess the position of the material. When the material characteristics change the sensor will perceive a change in signal but the position of the material is wrongly inferred. Every time the material characteristics change, the sensor has to be recalibrated to a new percentage of impermeability.

 ![Conventional edge sensor based on blocking principle](https://r2r.tech/sites/default/files/inline-images/Edge%20Sensor%20using%20blocking%20principle_0.JPG)

[The new sensor technology](https://r2r.tech/documentation/material-agnostic-fiber-optic-web-edge-sensor) with the light scattering and patented fiber optic sensing principle provides a true, absolute, precise, and digital position measurement of the web. The optical fiber optics act as filter that allows only the light signal that is in direct line with the fibers. A one dimensional pixel array collects and converts the light into digital voltage signal which is processed using an advanced digital signal processing algorithm.



Unlike the current sensor technology, the fiber optic sensors have the ability to detect the true edge of any type of material without the need for any manual adjustments of the sensor.

 ![Fiber optic edge sensor using light scattering principle](https://r2r.tech/sites/default/files/inline-images/Edge%20Sensor%20using%20light%20scattering%20principle_0.JPG)

An interesting difference between the current technology sensors and the fiber optic sensor is that the latter is encased in one arm. This breaks away from the traditional design of U-shaped sensor that requires an arm for signal emission and an opposite arm for signal capture. Fiber optic sensors have the signal emission and reception in the same arm, allowing for a compact design that reduces damage from impacts in the production line.



[Extensive testing has proven the capability of the sensor](https://www.youtube.com/watch?v=HS6wYKNfRbo) to be used with any material without calibration both in static and closed loop setup. Results confirmed the ability of the sensor to accurately detect the material, and in combination with the control algorithm of the guide, correctly position the material under various simulated disturbances.



Additionally, the true edge detection allows for higher precision and accuracy in web position correction. The new sensor technology allows for a true precision of 0.0635 mm, which the current technology cannot provide. Additionally, the sensor can be used for edge and center guiding, depending on the application required.



In general, fiber optic sensors offer the nonwoven sector an easier transition into higher speeds, handling thinner and lighter materials by providing a sensor that is more accurate and has the capability of handling different types of materials, or even materials that change characteristics within a roll during a production run. Moreover, this sensing technologies allow converters to reduce equipment inventory since one sensor can be used for multiple applications where a combination of ultrasonic, infrared and pneumatic sensors might be required.



However, there are other benefits that this technology opens. Higher precision opens opportunities for material savings as tolerances become tighter in order to run materials with narrower widths. In a future installment, we will discuss the latest developments in this technology. The fiber optic sensor is not only capable of edge and center detection, the same sensor can be used for line and contrast guiding which is very valuable for the label printing industry….



Want more information? Check out our [product page](https://www.r2r-tech.com/products/web-guides/aris-compact-web-guiding-systems), call us at +1 888-290-3215 or [contact us](https://www.r2r-tech.com/contact).

---

# On the Governing Equation for Web Tension with Out-of-Round Rolls

URL: https://r2r.tech/articles/governing-equation-web-tension-out-round-rolls.md

### Authors

 Carlo Branca, Prabhakar Pagilla, Karl Reid

### Publication Information

 Process of the Twelfth International Conference on Web Handling June 2013

### Abstract

 In roll-to-roll (R2R) manufacturing the presence of non-ideal elements, such as out-of-round or eccentric rolls, induces periodical oscillations in the web tension signal. Model simulations based on ideal elements do not exhibit these tension oscillations but can only follow the measured tension signal in an average sense. In order for the models to predict these measured tension oscillations due to non-ideal elements, the derivation of governing equations must consider a mechanism to include the correct behavior of the non-ideal transport elements. Continuing with our previous work on this topic presented at previous IWEBs, we present additional results that provide improvements to the web span tension governing equation which can better predict measured tension signals. In particular, this work is useful for tension control in the unwind section of the web line when the unwind material roll is often out-of-round. The governing equation for web span tension is typically derived using the law of conservation of mass by considering a control volume enclosing the web span, i.e., at any instant of time the variation of web mass in the control volume is equal to the difference of the incoming and outgoing material flow rates. If the web span is between two ideal elements the only way to induce changes in web span tension is with an imbalance in the web material flow. For ideal elements it is easily shown that the material flow rate is proportional to the difference of the peripheral velocities of the web on the surface of the rolls adjacent to the web span. When an out-of-round roll is at one end of the web span, two aspects make the derivation of the web tension governing equation different from the ideal case. First, because of the out-of-roundness of the roll, the span length adjacent to the roll is time-varying; variations in the span length induce web tension variations that are not associated with an imbalance in material flow. Second, the material flow rate is not proportional to the peripheral velocity of the web on the out-of-round roll and must be computed explicitly. Given a measure of out-of-roundness of the roll, due to the complexity of the problem it is difficult to derive a closed form expression for the material flow rate as a function of the roll position and velocity. A numerical algorithm for the computation of the material flow rate is presented in the paper. Based on the computation of the material flow rate and the algorithm for the computation of the span length adjacent to an out-of-round roll which was presented in the previous IWEB, a new governing equation for web tension is developed. Using this new governing equation a dynamic model for an experimental web line is developed and model simulations are conducted. To corroborate the model, experiments are conducted on the web line with an out-of-round unwind material roll. Comparison of the results from model simulations and experiments are presented and discussed.

---

# On-line Optimization-based Coordination of Multiple Unmanned Vehicles

URL: https://r2r.tech/articles/line-optimization-based-coordination-multiple-unmanned-vehicles.md

### Authors

 Rafael Fierro, Carlo Branca, John R Spletzer

### Publication Information

 Proceedings of the IEEE Networking, Sensing and Control March 2005, Pages 716-721

### Abstract



The objective of this work is to investigate on-line optimization-based coordination strategies for robot teams to efficiently accomplish a mission (eg, reach a set of assigned targets) while avoiding collisions. The multi-robot coordination problem is addressed by solving an on-line receding-horizon mixed-integer program to find some suitable inputs for the vehicles. Simulations results verify the feasibility of our approach.



[Link to the article](http://vader.cse.lehigh.edu/publications/icnsc05.pdf)

---

# Optimal Control of Web Guides Using a New Fiber Optic Edge Sensor

URL: https://r2r.tech/articles/optimal-control-web-guides-using-new-fiber-optic-edge-sensor.md

### Authors

 Aravind Seshadri, Prabhakar R. Pagilla

### Publication Information

 Conference: ASME 2008 Dynamic Systems and Control Conference
 January 1, 2008, Pages 1027-1034

### Abstract

 This paper discusses the development of a linear quadratic optimal control algorithm for web guides, and implementation of the control algorithm using web lateral position feedback from a new, experimental fiber optic sensor. The lateral dynamic model of the web and the measurement characteristics of the fiber optic sensor are conducive for a linear quadratic regulator design. The performance of the optimal control algorithm with web lateral position feedback from the fiber optic edge sensor is evaluated by conducting experiments on a web platform. Experiments were also conducted using the same controller but with an existing industrial infrared sensor for web lateral position measurement. Results from a series of comparative experiments indicate that the optimal control algorithm with feedback from the fiber optic sensor provides accurate lateral position regulation in the presence of disturbances, at various web transport speeds, and with web materials with different mechanical, physical and geometric properties. Based on the analysis of the web lateral dynamic model, recommendations for proper guide operation and selection of appropriate web transport conditions for good guiding performance are also discussed.

[Link to the Article](http://proceedings.asmedigitalcollection.asme.org/proceeding.aspx?articleid=1630064)

---

# Optimal Web Guiding

URL: https://r2r.tech/articles/optimal-web-guiding.md

### Authors



Aravind Seshadri and Prabhakar R. Pagilla



### Publication Information



J. Dyn. Sys., Meas., Control 132(1), 011006 (Dec 03, 2009) (10 pages) doi:10.1115/1.4000074



### Abstract



This paper presents an optimal web guiding strategy based on the dynamic analysis of the lateral web behavior and a new fiber optic lateral web position measurement sensor. First, a lateral dynamic model of a moving web is revisited with an emphasis on correct application of appropriate boundary conditions. Then the dynamic models of two common intermediate guides (remotely pivoted guide and offset-pivot guide) are investigated. The effect of various model parameters on lateral web behavior is analyzed and discussions on proper selection of the parameters are given. Based on the model analysis, we discuss the design of a linear quadratic optimal controller that is capable of accommodating structured parametric uncertainties in the lateral dynamic model. The optimal guide control system is evaluated by a series of experiments on a web platform with different web materials under various operating conditions. Implementation of the controller with a new fiber optic lateral sensor for different scenarios is discussed. Results show good guiding performance in the presence of disturbances and with uncertainties in the model parameters.



[Link to the Article](http://dynamicsystems.asmedigitalcollection.asme.org/article.aspx?articleid=1476552)

---

# Pneumo-Hydraulic Web Guides

URL: https://r2r.tech/articles/pneumo-hydraulic-web-guides.md

## What are Pneumo-Hydraulic Web Guides?



Many displacement guides, steering guides, unwind / rewind guides manufactured in the 1960’s, 1970's, 1980’s and 1990's were controlled using both pneumatic and hydraulic control systems which are often referred to as pneumo-hydraulic web guides. These web guide were really common before the mass adoption of the electronic (analog and digital) controllers and electric actuators. A lot of these units were predominant in blown film lines, extrusion lines, flexographic printing presses and even in paper converting machines. 



### Pneumatic Sensors



The pneumo in the pneumo-hydraulic web guides refers to the air signal used by the web edge sensor. The sensor typically has two pneumatic lines: a pressure line, that provide pressurized air to the sensor, and the signal line, that collect the attenuated signal from the sensor to the control unit. The web edge position is determined by observing the change in air pressure while a web material is passed in between the throat (fork or the arms) of the sensor. The control unit typically has an air pressure adjustment system which maintains the required pressure for the sensor to work effectively. In order to maintain proper pressure it is recommended that the pneumatic lines are as close to the control unit as possible and typically no more than 12 feet or 3.65 m. 

 ![Pneumatic Web Edge Sensor](https://r2r.tech/sites/default/files/inline-images/Pneumatic-Sensor.png)

### Working Principle of a Pneumatic Web Edge Sensor



These web edge sensors work on a very basic sensing principle: the amount of signal received by the signal line is directly proportional to the location of the web inside the sensing window. When the web is completely outside the sensing window, pretty much no signal is attenuated. As the web edge moves inside the sensor window, the air signal is blocked and hence the signal attenuates. The magnitude of signal attenuation provides a signal proportional to the location of the web edge.



### Advantages of Pneumatic Web Edge Sensors



These web edge sensors have several advantages, mainly because of the type of signal used for web edge detection. Unlike optical sensors, these sensors are not affected by the opacity of the materials. Moreover, since a constant stream of air is flowing through the sensor throat, these edge sensors are not affected by the dust in the environment. Finally, with air being the only signal, these sensors can be used in hazardous environments since they are intrinsically safe. The advantages of these web edge sensors are summarized below:



- Clear and opaque homogeneous materials can be detected by the sensor
- Unaffected by dust
- Intrinsically safe and may be used in hazardous environments



### Disadvantages of Pneumatic Web Edge Sensors



In spite of some advantages, these pneumatic edge sensors are not a popular sensor of choice for new builds. There are several reasons to avoid these sensors. 



One of the main reasons to avoid pneumatic edge sensors is the accuracy of the measurement. Accuracy is an indication of the closeness of the sensor measurement to the true/real position. Since the sensor responds to change in air pressure (due to web movement) the accuracy of the measurement depends on the ability to maintain a steady air pressure. Often this is an issue with clog, line pressure drops, etc. The second main reason to avoid this sensor is its limited resolution. The resolution is the minimum difference in web position that can be perceived by the sensor due to the pressure change. This resolution is highly dependent on the quality of the air pressure line and even the web material being detected. The third reason to avoid these sensors is the limited sensor range. Range is the maximum web position variation that can be perceived by the sensor. Typically these sensors have a range of no more than 0.5 in or 12.7 mm, since wider range would affect the minimum pressure required for the sensing principle to work.



Apart from these key disadvantages, the pneumatic web edge sensors also have some other shortcomings or annoyance. These sensors are often bulky, rigid and heavy. So moving them around is not an easy task. Even if they can be moved, they have to be located close to the power unit because of the pressure line requirements. Typically they are recommended to be no more than 12 ft of the supply line. Since these power units are noisy, the environment around these web guides are noisy as well. Sometimes the sensor may be clogged because of contamination and this can significantly affect the web guiding performance. Finally the sensor throat, the distance between the two arms or forks, are typically small in order to maintain the required pressure. Small throats are often an issue while threading the web after a changeover. Moreover, small throat can also snag a splice with a tail, potentially causing damage to the web or the sensor itself. 



Finally, the sensors are not suited for certain environments (vacuum) or with certain materials such as porous materials, or delicate materials. To summarize the many disadvantages with the pneumatic web edge sensors are:



- Inaccurate sensor measurement
- Low resolution
- Small range
- Bulky, rigid, heavy and not easy to move around
- More maintenance required than electronic sensors
- Not suited for vacuum environment
- Not ideal for porous materials or delicate materials



## Hydraulic Actuators



The hydraulic in the pneumo-hydraulic web guides refers to the hydraulic actuator which includes a hydraulic cylinder powered by a hydraulic power unit. 



Typically a hydraulic power unit and the control system includes a reservoir for the oil, a hydraulic pump (powered by an AC motor) with filters and pressure gauge, a servo valve that controls the flow of oil to the hydraulic cylinder, and the hydraulic lines that supply the oil to the hydraulic cylinders. Depending on the power requirement, the complete hydraulic power unit may weigh from 100 lb (45 kg) to about 250 lb (113 kg). 

 ![Pneumo-hydraulic Power Unit with Hydraulic Cylinder Actuator](https://r2r.tech/sites/default/files/inline-images/Power-Unit.png)

The servo value is the controller in the pneumo-hydraulic web guides. The signal from the pneumatic sensor is used by the servo value to direct the hydraulic fluid through the two hydraulic lines to position the hydraulic cylinder (or the web guide) at the desired location. 



### Advantages of Hydraulic Actuators



The main advantage of using hydraulic actuator is the larger amount of thrust or force the actuators can deliver. Higher thrust in turn means that the actuator can reach higher acceleration or high correction rates quickly. The web guide response can be high with hydraulic actuators. Hence these actuators are still predominantly used in metal lines where the mass or the load the web guide needs to move is large.



### Disadvantages of Hydraulic Actuators



Nowadays the use of hydraulic power units are becoming less common because of a variety of disadvantages. 

 ![Pneumo-hydraulic power unit leaking oil](https://r2r.tech/sites/default/files/inline-images/PowerUnitLeak-01.png)

Leaks are the biggest problem with pneumo-hydraulic web guides. The leak in the high pressure system is not about “if” but “when” a leak would occur. Hydraulic oil leak can happen at the power unit or at the cylinder and anywhere in between. And the leak can occur due to seal failure, gasket failure or o-ring failure or pressure line failure. The leaks cause a mess, safety hazard with slippery surface. More importantly they contaminate the previous product that is being manufactured in the production line. All of these directly affect the bottom line of the operation. 



Apart from the leak, these systems are also costly to operate, needing frequent maintenance. It is necessary to change the seals, gaskets, o-rings, filters, maintaining clean oil, flushing the system, etc.on a periodic schedule. The maintenance budget includes the cost associated with spare parts, consumables as well as the downtime required for preventive maintenance. 



Even though the hydraulic units can provide high thrust at incredible acceleration, they lack precision and repeatability. With problems maintaining constant pressure in the system, the repeatability and precision are the scapegoats. It is also not uncommon to see the actuator move at different speeds based on the direction of the stroke. This is mainly due to the imbalance in the servo control value. This does affect the overall guiding performance.

 ![Hydraulic cylinder actuator leaking at the web guide steering frame.](https://r2r.tech/sites/default/files/inline-images/Cylinder-Leak-01.png)

Similar to the pneumatic system, the hydraulic system is also affected by contamination, i.e., contamination of oil, clogging, etc. Overall the disadvantage of the hydraulic actuators or hydraulic control systems are:



- High maintenance cost 
- Leaks causing mess, slip hazard
- Contamination of the product and the environment
- Repeatability issues and precision issues
- Overall high cost of ownership



The hydraulic web guides are overly complex for most applications where the thrust requirement is below 2000 lbf (9000 N). The disadvantages outweigh the benefits and for applications with less than 2000 lbf thrust, electric actuators with electronic control systems are the best choice. The state-of-art sensors, controllers and actuators can provide a significant performance improvement at a fractional of the overall cost of ownership of the pneumo-hydraulic systems.



## How to Stop the Bleeding?



If you operation is still relying on pneumo-hydraulic units you might be leaving a lot of money on the table. Consider upgrading to the latest in the [sensor](https://r2r.tech/products/sensors), [controller](https://r2r.tech/products/roll-2-roll-controller) and actuator technology with [retrofit kits](https://r2r.tech/products/web-guide-replacement-kit) from Roll-2-Roll Technologies. The retrofit kits are designed to keep the existing guide frame structure while replacing just the sensor, actuator and the controller. This upgrade would be less than what you would need to rebuild the pneumo-hydraulic system. Best of all your don’t have to rely on the old technology to keep your line running. 



Call us today to find out more about how we can help with this upgrade.

---

# The Impacts of the Latest Developments in Sensing Technology

URL: https://r2r.tech/articles/impacts-latest-developments-sensing-technology.md

Every generation has a revolution and for years U-shaped sensors were the standard in edge sensing technology. Now the next generation in web sensing technology is here. Materials are getting thinner, lighter and processes are getting faster. Is your web guiding technology up to date for this challenge?



Time consuming set-ups, inefficient processes to change materials, and lack of precise edge detection because of web material property changes are some of the major problems faced in the converting industry. One of the innovative technological developments of 2015 addresses these problems providing a major leap in web guiding through a new sensor technology.

 ![Next generation web edge sensing technology](https://r2r.tech/sites/default/files/inline-images/Next%20Generation%20of%20Web%20Edge%20Sensing%20Technology.jpg)

To the converter, faster speeds and thinner materials mean more production at less cost. At the same time, it presents an interesting challenge to web guide manufacturers as sensors have a more difficult task in detecting the edge. Web guiding is one of the important, yet often overlooked, material control components, and the detection of the position of the web is of great importance. As such a major element in the material handling, web guides need to react faster to the disturbances present in the converting process.



At the end, what this translates to in the converting industry is operational problems such as misprinted materials, misplaced layers of material, material wrinkling or tears, and manual adjustments of the sensor controls due to changes in material thickness, and product aesthetic problems such as misplaced resealable closures. All in all time, money and products are wasted with inaccurate sensing technology. The new technology eliminates these problems for the converting industry.



Today’s sensor technology is based on the principle of signal blocking. They provide a relative, inferred, analog measurement. Sensor systems based on this principle depend on the assumption that the material is 100% impermeable to the emitted signal. However, materials are often not 100% impermeable and this requires calibration of the sensor for each type of material. Furthermore, this type of technology can only infer the position of the material. When the material characteristics change the sensor will detect the signal but the position of the material is wrongly inferred. Every time the material characteristics change, the sensor has to be recalibrated to a new percentage of impermeability.



The blocking principle requires an emitter in one arm and a receiver in the opposite arm. The web runs between the arms and blocks an ultrasonic, pneumatic, or infrared signal.

 ![Edge sensors using blocking principle](https://r2r.tech/sites/default/files/inline-images/Edge%20Sensor%20using%20blocking%20principle.JPG)

Until now, sensors that operate under the blocking principle have saturated the market. After more than ten years of research and development, Roll-2-Roll Technologies LLC, has come out with a commercial web edge sensor that uses the light scattering and spatial filtering technology to accurately measure the web edge position.



The new sensor technology with the light scattering and patented fiber optic sensing principle provide a true, absolute, precise, and digital position measurement of the web. The fiber optics act as filter that allows only the light signal that is in direct line with the fibers. A one dimensional pixel array collects and converts the light into digital voltage signal which is processed using an advanced digital signal processing algorithm. Unlike the current sensor technology, the fiber optic sensors have the ability to detect the true edge of any type of material without the need for any manual adjustments of the sensor.

 ![Fiber optic edge sensor using light scattering principle](https://r2r.tech/sites/default/files/inline-images/Edge%20Sensor%20using%20light%20scattering%20principle.JPG)

Extensive testing has proven the capability of the sensor to be used with any material without calibration both in static and closed loop setup. Results confirmed the ability of the sensor to accurately detect the material, and in combination with the control algorithm of the guide, correctly position the material under various simulated disturbances. Additionally, the true edge detection allows for higher precision and accuracy in web position correction. The new sensor technology allows for a true precision of 0.0635, which the current technology cannot provide. Additionally the sensor can be used for edge and center guiding, depending on the application required. Another key feature of this sensor technology is that the same sensing principle can be used for line sensing, contrast sensing, thread detection and counting. Unlike the traditional line sensors or contrast sensors, the new fiber optic sensor technology does not require any teaching and is unaffected by the ambient light conditions and reflective properties of the material.



In general, fiber optic sensors offer the converting industry an easier transition into higher speeds and thinner materials by providing a sensor that is more accurate and has the capability of handling different types of materials, or even materials that change characteristics within a roll during a production run. Moreover, this sensing technologies allow converters to reduce equipment inventory since one sensor can be used for multiple applications, such as line, contrast and edge guiding, where a combination of ultrasonic, infrared and pneumatic sensors might have been required. However, there are other benefits that this technology opens. Higher precision opens opportunities for material savings as tolerances become tighter in order to run materials with narrower widths. 

---

# Unwind and Rewind Guides: Design and Installation Considerations

URL: https://r2r.tech/articles/unwind-and-rewind-guides-design-and-installation-considerations.md

## What are Terminal Web Guides?



Terminal web guides are devices used at the entry and exit of a roll-to-roll machine to appropriately align the web to the desired cross machine location. Entire roll of the web, on the unwind/rewind stand, is moved along the cross-machine direction for the proper alignment.



There are several names or terms commonly used for these terminal guides including: shifting stand, shifting base, shifting sidelay, uncoil and recoil, payoff and tension reel, and roll positioning stands. In an unwind web guide the wound roll is positioned so that the web is fed into the machine at the right location. While in a rewind guide, the wound roll on the stand, chases the web so that the web is wound on the roll in the right position despite movement in the incoming web. Even though both these web guides appear to behave the same way there are some important differences, especially with installation and control system design. Appropriate design of a terminal guide should include proper mechanical design and control system design based on the process parameters. This document is intended to provide information that would help designers.



## Unwind Guiding

 ![Unwind guiding system with a fixed sensor and a moving idler](https://r2r.tech/sites/default/files/inline-images/Unwind-guiding.png)

With an unwind guide, the entire unwind roll assembly supported on a stand is moved in the cross machine direction. Typically the stand is mounted on precision low friction linear bearings and moved with an actuator. A sensor is installed on the fixed machine frame and is typically located just downstream of the last idler that shifts with the unwind stand. The feedback from the sensor is used to move the unwind stand so that the web is at the desired cross machine location within the roll-to-roll machine. Following are list of items to check for proper installation of unwind guides:



- Ensure that the sensor is fixed and does not move with the unwind shifting stand.
- Ensure that the sensor is located just downstream of the last shifting idler on the unwind stand.
- Install the sensor as close as possible to the last shifting idler.
- Install at least one shifting idler on the unwind stand so that the diameter variation does not cause plane change at the sensor.



## Rewind Guiding

 ![Rewind guiding installation with a moving sensor](https://r2r.tech/sites/default/files/inline-images/Rewind-guiding.png)

In rewind guiding, the winding roll chases the web and it is technically not guiding the web. The sensor is mounted to the rewind stand so that when the stand translates the sensor also moves. The purpose of the control system is to keep the relative position between the incoming web and the rewind stand constant, so that the resulting wound roll is straight. By installing the sensor on the translating rewind stand, a measurement of the incoming web relative to the stand is available. However, if the sensor is installed to the fixed machine frame the relative position between the web and the stand would be lost. This will not close the feedback loop. Hence for rewind applications, the sensor should always be installed on the moving rewind stand. The checklist for proper rewind guiding installation include:



- Ensure that the sensor is mounted on the moving rewind carriage.
- Ensure that the fixture for mounting the sensor is stiff.
- Ensure that the sensor is installed to observe the web just upstream of the last fixed idler before the rewind stand.
- Install the sensor such that it is as close as possible to the last fixed idler upstream of the rewind stand.



## Mechanical Design Considerations



Mechanical design is critical since large mass is moved in this type of web guide; especially the mechanical design requires consideration for the speed, acceleration, thrust, structural rigidity, friction, etc.



### Mechanical Structure Stiffness and Rigidity



The main consideration for the mechanical structure relates to the structural rigidity of carriage that supports the roll. Poorly designed carriages can cause significant vibration and mechanical resonance if the stiffness of the system is not designed properly. Specifically, the natural frequency of the guide structure along with the roll mass should be designed to be well over the natural frequency of the control system to avoid any mechanical resonance. For a terminal web guide the natural frequency of system is similar to a mass-spring system which is given by

 ![Natural frequency equation](https://r2r.tech/sites/default/files/inline-images/natural-frequency-equation.png)

where Ke is the equivalent stiffness of the terminal guide structure, M is the mass of the terminal guide structure along with the roll (W is the weight), and fn the natural frequency of the terminal guide structure in Hz. As seen from the natural frequency equation, it is important to have a stiffer mechanism when a larger mass is needed to be moved.



Apart from the stiffness of terminal guide structure, the design should also pay attention to the stiffness of the actuator, the actuator mounting or any support plate for mounting the actuator. These individual component stiffnesses contribute to the equivalent stiffness which can be modeled as equivalent stiffness of springs in series. It is evident that the least stiff element is going to have a significant influence on the overall effective stiffness of the assembly.

 ![Equivalent Stiffness Equation](https://r2r.tech/sites/default/files/inline-images/equivalent-stiffness-equation.png)

Natural frequency between 25 Hz to 50 Hz would be an ideal choice for the terminal web guide since most control systems for these terminal guides are typically designed to have a natural frequency between 8 Hz to 15 Hz.



### Actuator Type



Legacy actuators for unwind and rewinds were hydraulic and at times pneumatic cylinders. However with the advances in controls and drives, the state-of-the-art stepper and servo actuators can provide benefits such as smooth response at variable speed as well as full force/thrust at zero speed, while eliminating the need for plumbing and the possibility of product contamination with hydraulic fluid leak. It is critical to choose an appropriate actuator based on the desired dynamic response by considering the mass to be moved. Moreover the stiffness of the actuator (piston/rod and the mounting) should also follow the same constraints as the stiffness of the carriage to avoid any issue with resonance.



Most electro-mechanical actuators convert the rotary motion of a motor into linear motion at the actuator using some kind of a screw/nut mechanism. Typically a rod style actuator is used where the nut is connected to a rod that extends and retracts to transmit power. Low cost actuators typically employ a simple lead screw mechanism with a metal or plastic nut. These actuators cannot provide high thrust or high dynamic response because of the nut wear that limits the thrust and creates backlash. Higher end actuators would employ ball screws (with recirculating balls) or roller screws or planetary roller screws that provide higher thrust as well as lower backlash for superior dynamic performance. These high end actuators may also have anti-backlash (spring loaded nut) and anti-rotation (splines to prevent nut rotation) provisions builtin.



![Reverse parallel mount actuator](https://r2r.tech/sites/default/files/inline-images/rp-actuator.png)In unwind and rewind guiding applications two types of motor mounting options are common. In the reverse parallel configuration the motor shaft and the screw axis are not collinear, but they are parallel to each other. This is a compact configuration with the overall actuator length between the mountings to be smaller than the other inline configuration. Belt/timing pulleys (with 1:1 to 8:1 ratio) are used to transmit the torque from the motor to the screw. Inline mounting of the motor and the screw is also common but the overall length of the actuator is longer. Gear boxes are typically employed with inline mounting of the motor and the screw. The motor shaft and the actuator screw axis are collinear.



Using the belt ratio between the pulleys (or gear box ratio) along with the screw pitch, mechanical advantage is gained to provide high thrust at the actuator. This mechanical advantage allows the use of lower torque motors but since the power transmitted is the same, higher trust can only be provided at lower speeds. By increasing the output power of the motor, higher thrust can be transmitted at higher speeds.



### Motor Type



While moving a large mass simple DC motors may not be an ideal choice. A servo motor or a stepper motor with advanced drives (microstepping) and controller (motion profiles) may be necessary. Servo motors provide the highest performance since the thrust can be maintained at high speeds. However, tuning a servo motor is load dependent and such a tuning might need to happen in the field to ensure proper performance.



A properly designed stepper motor system (speed and position motion profiles) can provide comparable performance at lower cost. By taking advantage of the fact that stepper motors can provide high torque at low speeds (less than 1000 rpm), when compared to a similarly sized servo motor, mechanical gearing and lead screw pitch can be designed to meet the thrust/speed requirements of a terminal web guiding system. By utilizing advanced stepper drive and controller capabilities such as microstepping, current chopper control, speed ramping, anti-resonance modes, load based current control, etc., the low cost stepper can provide similar performance of a servo motor for terminal guide actuators.



The main consideration irrespective of the type of motor is the inertial effect of moving a large mass and sudden direction changes required for web guiding. Appropriate compensation for backdriving or back emf generated during deceleration should be implemented. With advanced stepper and servo drives, coasting can be avoided and breaking by means of deliberate deceleration can help reduce regeneration problems. Additionally, a linear power supply or a regenerative power supply can absorb some of the energy generated during deceleration. Regeneration breaks can also be used to dissipate the excess energy while a switching power supply is used.



### Actuator Sizing



The actuator must be sized appropriately to ensure that enough thrust is available from the actuator to move the mass at the desired speed. The thrust needed should overcome the breakaway force due to the bearing friction as well as to accelerate the mass to achieve desired dynamic response.



#### Breakaway Force



The breakaway force is essentially the force required to move the mass from rest to a non-zero velocity. This is the static friction force which is a function of the coefficient of friction and the weight of the carriage along with the roll of the web.



The coefficient of friction depends on the type of bearing used and the relative alignment of the sliding/rolling surfaces. It is typical to assume 0.25 as the coefficient of friction for purely sliding surfaces. These include plain linear bearings on appropriate metal shafts with certain surface finish or roughness. These are not common with terminal guides and should be avoided especially with large loads. Since rolling friction is much lower than sliding friction, ball or roller bearings are commonly used in the linear bearings for terminal guide carriages. These have significantly lower coefficient of friction ranging from 0.01 to 0.08. Seal drag, lubrication viscosity and any pre-loading can increase the coefficient of friction for roller or ball bearings. Apart from the coefficient of friction of individual linear bearings, the alignment of the various bearings with respect to the rod/shaft/profile on which the bearings slide has an effect on the breakaway force. Any misalignment with the installation of the bearing and the respective slide surface could contribute to additional friction. Hence the overall breakaway force is a function of the type of bearing as well as the relative alignment of the individual bearings with respect to the carriage.



The breakaway force can be directly measured by loading the carriage with the roll and measuring the force required to move the carriage as it moves over the linear bearings. A simple spring (push or pull) weight gauge can be used to measure the breakaway force. And most gauges would have a provision to measure the maximum force.



#### Force for Acceleration



Apart from the force to overcome the breakaway force, additional thrust is required to accelerate the mass to meet the desired performance requirements. Based on Newton's law the required thrust is directly proportional to the mass and the desired acceleration. The desired acceleration can be obtained with the knowledge of the magnitude and the type of disturbance expected. Most web guides, and specifically terminal web guides, are mainly intended to remove steady state disturbances. The dynamics response for such disturbances are not that demanding compared to dynamic disturbances such as a sinusoidal disturbance.



One parameter that is often misused is the actuator correction speed. The speed is irrelevant if the web guide cannot accelerate fast enough to get to the maximum speed. Web guides typically make small corrections with quick change in direction. In these scenarios, acceleration is an important factor.



For example, a sinusoidal disturbance of magnitude 5 mm (approximately 0.2 in) at a frequency of 2 Hz requires the actuator to have an acceleration of at least 790 mm/sec^2 (7.7 in/sec^2) to reject the disturbance. The same magnitude disturbance at 0.5 Hz frequency would require only 49 mm/sec^2 (1.94 in/sec^2) of acceleration. Hence it is important to not only know what the maximum speed of the actuator is, but also the maximum acceleration possible.



Finally, the acceleration is an important factor when using the terminal guides with oscillation application. In these applications the guide is deliberately made to oscillate to prevent gauge band variations across the width. In such applications both acceleration and speed must be chosen properly based on the power and thrust output of the actuator.



A good understanding of the application requirement will enable designers to properly size the actuator based on both the breakaway force and the acceleration requirement.



### Actuator Mounting



Actuator mounting is an important part of the terminal guide design. As mentioned earlier, the stiffness of the actuator and the actuator mounting is critical to avoid resonance is![Reverse Parallel Mount Actuator](https://r2r.tech/sites/default/files/inline-images/RLA-actuators.png)sues with terminal web guides.



Two common mounting include, fixed and floating mounting. In a fixed mounting the actuator is mounted rigidly to a fixed base and the rod end of the actuator is also mounted rigidly to the moving carriage. This type of mounting can provide the best performance since there is no play in the mounting. However, the alignment of the mounting becomes extremely critical in the remaining five degrees of freedom. The most common problem with this type of mounting is the binding of the actuator due to misalignments. This biding can cause side loads on rod style actuators leading to premature failure. To reduce the effect of side loads and binding issues some actuators have parallel guideways or raceways to absorb the side load and prevent it from reaching the actuator rod.



Floating mounts for the actuator reduce the alignment issues by providing an additional degree of freedom in the mounting. An eye mount or a clevis mount is used so that a pin can connect these mounts to provide the additional degree of freedom in alignment. This additional degree of freedom allows the actuator to float or pi![Floating mount actuators](https://r2r.tech/sites/default/files/inline-images/floating-mount-actuators.png)vot about the pin when the actuator extends and retracts. It is common to have both the connections (between the actuator and the moving carriage, as well as between the actuator and the fixed machine frame) to have a floating/pivoting mount; however in some cases one of them might be a fixed mount and the other floating. Some of these might also have a spherical eye, which provides another degree of freedom for mounting.



One of the main issues with the floating mount is the play in the connection. Any play in the connection can significantly reduce the achievable dynamic response. One other issue comes with improper installation. Care needs to be taken to ensure that the pin axis is installed properly to allow for the actuator to pivot in the correct plane. It is not uncommon to see such improper installation. This is mainly seen with spherical eyes since that extra degree of freedom provided by the spherical eye causes confusion with the plane of motion.



## Summary



Several important aspects of a terminal guide design have been discussed in this article. With this understanding the designers and practitioners can get the best possible performance for their application needs. Roll-2-Roll Technologies is here to help with any of your design needs, questions and concerns about terminal guide installation.



Please call us today (+1-888-290-3215) to find out more about how we can help with your new unwind/rewind guiding system installation or upgrade.

---

# Web Flutter Measurement Sensor

URL: https://r2r.tech/articles/web-flutter-measurement-sensor.md

### Authors

 Aravind Seshadri, Prabhakar R. Pagilla

### Publication Information

 Sensors Journal, IEEE
 Volume:9 , Issue: 7, July 2009, Pages 834-835

### Abstract

 A novel sensor to measure web flutter is proposed in this letter. The sensing principle is based on scattering of light and directionally sensitive coupling properties of optical fibers. A linear array of optical fibers, oriented appropriately, is used to collect light scattered from a web. The flutter amplitude is determined by observing the amount of light transmitted by the fibers in the fiber array. Experiments were conducted to demonstrate the ability of the proposed sensing strategy in measuring web flutter with different kinds of web material.

[Link to the Article](http://ieeexplore.ieee.org/xpl/login.jsp?tp=&arnumber=5073241&url=http%3A%2F%2Fieeexplore.ieee.org%2Fxpls%2Fabs_all.jsp%3Farnumber%3D5073241)

---

# Web guides or web guiding systems overview

URL: https://r2r.tech/articles/web-guides-or-web-guiding-systems-overview.md

> Web materials are not perfect, and neither are converting machines. Web guides are needed to reduce waste due to web misalignment.



## Web Guiding Principles



Video courtesy of Jerry Brown at [normalentry.com](http://normalentry.com)



Web guides are able to steer or guide the web because of the Normal Entry rule. This rule refers to the propensity of the web to align itself perpendicular to the axis of rotation of the roller it is approaching; provided there is no slippage between the web and the roller. Hence the web guides steer or guide or displace the web by deliberately changing the axis of rotation of the roller(s) on the web guide.



The Normal Entry rule is applicable to any fixed or moving roller on a roll-to-roll converting machine. Hence any roller that is misaligned within the machine would cause the web to move.



[Learn More](https://r2r.tech/articles/web-guiding-system-why-what-where-and-how)



## Basic Components of Web Guides



**Guide mechanism** is typically a mechanical structure that makes contact with the material and moves the web material. Depending on the type of web guide, the shape and size of the guide mechanism are varied. An actuator moves the web guide mechanism to guide the web at the appropriate location.



A [web edge sensor](https://r2r.tech/products/aris-web-position-sensor) or a web position sensor detects the position of the web material. This measurement is used to determine and control the desired position of the material.



The [Controller](https://r2r.tech/products/scu5-controller) is the brain of the web guiding system. The controller uses the measurement from the sensor to determined the necessary corrective action. The controller then command the actuator to move the guide mechanism to actively control the web position.

 ![Basic components of web guides](https://r2r.tech/sites/default/files/inline-images/Web%20guide%20diagram_1.jpg)

## Displacement Guides or Offset-Pivot Guides

 ![Displacement or offset-pivot web guide](https://r2r.tech/sites/default/files/inline-images/Web-Guide-With-Webs-And-Sensor-Copper--01.png)

[Displacement guides](https://r2r.tech/products/displacement-guides) are the most common intermediate web guides used in the industry. These web guides are the workhorse of intermediate web guides because of their design and simplicity. The design includes two rollers on the web guide mechanism that rotate about an imaginary pivot point. Hence they are also called an offset-pivot guide.



A well designed displacement guide with proper installation can significantly reduce the stresses on the web. The two roller guide platform enables pure displacement of the web with minimal bending stresses on the web. This pure displacement action enables web correction with minimal entry and exit span requirements.



[Learn More](https://r2r.tech/products/displacement-guides)



## Steering Guides or Remotely Pivoted Guides



[Steering Guides](https://r2r.tech/products/web-guides/steering-guide)(https://r2r.tech/products/narrow-web-steering-guides) are typically used in specific applications where a displacement guide would not work. These applications include processes with long entry spans, such as an exit of an long oven. These guides have one or two rollers that travel over an arc. The center of the arc is typically located in the upstream span. Hence they are also called as remotely pivoted guide.



The [steering guide bends the web in the entry span to create the lateral motion](https://r2r.tech/videos/demonstration-simple-narrow-steering-web-guide). The amount of bending depends and ultimately the amount of correction is dependent on the radius of the arc, the span length or the entry span and also the bending stiffness of the web material. Even though the steering guide looks simple, the installation of a steering guide requires a lot of attention.



The steering guide has one advantage especially in installations with long entry spans. Since the correction is due to bending, the steering guide can affect the web position within the upstream entering span.



[Learn More](https://r2r.tech/products/steering-guides)

 ![Steering guide for narrow web applications](https://r2r.tech/sites/default/files/inline-images/Steering%20Guide%20Assembly-TR-10-01_0.png)

## Unwind Guides

 ![Unwind web guide](https://r2r.tech/sites/default/files/inline-images/Unwind-web-guide.png)

Unwind guides are a type of terminal web guides that align the web fed into a converting machine. Unlike the terminal web guides, no pivoting motion is necessary for these types of web guides. Typically a carriage or a side lay that carries the entire roll of web material is moved in the cross machine direction. The carriage is typically mounted on high precision linear bearings. High thrust linear actuators that can move the entire carriage plus the wound roll are typically used.



Unwind guides usually include an idle roller attached to the moving carriage. This idle roller is used to stabilize the web so the sensor sees a constant web without any plane changed caused by the roll diameter changes. The web edge sensor is mounted on a fixed machine frame.



## Rewind Guide



Rewind guides are used at the end of a roll-to-roll machine. The web wound on the roller is guided to ensure that the wound roll is not telescoping. Rewinds guides are becoming less common since they are being replaced by intermediate guides.



Rewind guides are similar to unwind guides. An actuator moves a carriage supported on precision linear bearings to guide the winding roll. However, a rewind guide does not guide the web. Rather the rewind guide chases the web to align the different layers of the wound roll. Hence in order to chase the web, the sensor is mounted on the moving carriage and the idle roller is attached to the fixed frame of the roll-to-roll machine. The way the sensor and the idle roller are mounted is the key difference between unwind and rewind guides.

 ![Unwind/Rewind Guide](https://r2r.tech/products/unwind-rewind-guide)(https://r2r.tech/sites/default/files/inline-images/Rewind-Guide_0.png)

## Finding the Best Web Guiding Equipment for Your Operation

As we search for the most appropriate equipment for our operation, we are faced with the task of selecting from myriad options based on technical data and specs. Through these data, [measurements of accuracy, precision, linearity and resolution](https://r2r.tech/articles/accuracy-precision-linearity-and-resolution-web-guiding-understanding-terminology), manufacturers are trying to present the benefits of their products based on the device performance profile. However, sometimes what appears to be the best offer, based on what looks to be the best technical data, might not really be the best. The technical data can even be irrelevant information when considering performance. See [performance indicators](https://r2r.tech/articles/accuracy-precision-linearity-and-resolution-web-guiding-understanding-terminology) relevant to your system and how to apply this information to your applications.

---

# Web Guides Selection and Installation Tips

URL: https://r2r.tech/articles/web-guides-selection-and-installation-tips.md

> Correct selection and installation of web guides is important and shouldn't be overlooked.



Web guides are typically worry free once they are get up and running. However, selecting and properly installation a web is critical to ensure that the web guides are worry free. With a variety of web guide available in the market it is necessary to understand a few fundamentals to make the correct selection. In this article a few handy tips and rules of thumb are shared to make your installation easier.



## Importance of proper roller selection



### Roller Diameter



The diameter of the roller is dependent on the web speed and the type of material.



- Larger diameters are necessary for high web transport speed. The larger diameter reduces the rotation speed or revolutions/minute (rpm) of the rollers. Lower revolutions/minute reduces: the bearing wear, issues with eccentricity, issues with balancing, etc.
- Thicker webs or composite webs may require larger diameter to increase the radius of curvature necessary to wrap the web around the rollers.
- Thin and light materials (low modulus webs) on the other hand may require low inertia (aluminum or carbon fiber rollers) with low friction bearings to reduce any drag from the roller.



### Surface Roughness and Smoothness



The smoothness or the surface roughness of the rollers also play a critical part in web guiding.



- Grooved rollers help eliminate air entrainment. Especially with non-porous webs such as plastics, grooved rollers help with better traction on the web.
- Smooth rollers on the other hand may be needed for delicate webs such as thin foils. Grooved surfaces may create a permanent impression on the foils because of the uneven elongation around the grooves.

 ![Roller selection for web guiding and web handling applications](https://r2r.tech/sites/default/files/inline-images/Roller-for-web-handling-applications_0.png)

## Type of Web Guides



![types of web guides](https://r2r.tech/sites/default/files/inline-images/types%20of%20web%20guides-01_0.png)

  

Depending on the location where the guiding is required, there are four different types of web guides available. Displacement guides, steering guides, unwind guides and rewind guides.



### Displacement Web Guides



[Displacement guides](https://r2r.tech/products/displacement-guides) should be chosen as the first option wherever possible. If properly installed, the [displacement guides impart the least amount of stress on the web](https://r2r.tech/articles/web-guiding-system-why-what-where-and-how). These web guides position the web by directly displacing the web rather than bending the web. Hence they are the best choice for guiding. Situations where displacement guides cannot be used include: correction after a long span, locations with web wrap constraints, and locations with space and installation constraints. 



### Steering Guides



[Steering Guides](https://r2r.tech/products/web-guides/steering-guide)(https://r2r.tech/products/narrow-web-steering-guides) are ideal for situations where guiding after a long span is desired. These guides bend the web that enters the steering roller(s). The magnitude of steering depends on many factors including: web speed, web stiffness, guide installation (raceway angle), entry span length, etc. Since the steering action imparts stresses on the web, it is very critical to properly install the web guide to prevent web breakage.



### Terminal Guides



Unwind and rewind guides are used at the entry and exit of the machine. Typically the roll stand, that supports the raw material roll, is mounted on precision linear raceways. to minimize the friction necessary to move the guides. These terminal guides are simple, however the dynamic response is limited because of the force required to move the roll inertia.



## Proper Installation: Displacement Guides



### Entry and Exit Spans



Displacement web guides can have short entry and exit spans which may be of different lengths. A minimum of 1 web width is necessary for most applications. However, long spans lengths are needed for stiffer materials such as metals.



### Web wrap



A 90° wrap at the entry and exit of the guide roller is ideal. This 90° wrap enables pure twisting in the entry and exit spans, thereby imparting the least amount of stresses in the web. A small deviation from the ideal 90° wrap is acceptable. Apart from bending and stressing the web, the deviation from normal condition also affects the lateral correction speed.

 ![Displacement-Guide-installation-guidelines](https://r2r.tech/sites/default/files/inline-images/90%20degree%20wrap-01.png)

## Entry and exist span lengths: Steering Guides

 ![Steering guide installation guidelines](https://r2r.tech/sites/default/files/inline-images/steering%20guide%20wrap-01.png)

### Entry and Exit Spans



Steering guides require long entry spans. Depending on the stiffness of the web, the entry span length required may be from 3x to 10x the web width. Too short of a span may result in slack and tight edges or web wrinkles.



Since the steering guide bends the web, the moment transfer from the steering action can travel both upstream and downstream of the web guide. Hence the pre-entry, entry and exit span lengths are important design parameters. A rule of thumb is to have a pre-entry span shorter than the entry span. And the exit span is at least 1x web width.



### Web wrap



At least 90° wrap at exit of the steering guide roller is ideal. Because of the upstream moment transfer, the pre-entry roller may also require a wrap of no less than 45° and an ideal wrap of 90°. Additionally the plane of the entry span should be parallel to the plane where the roller platform moves. A plane change of no more than ± 20° may be acceptable.



## Type of Guiding



### Web Edge Guiding



Web guiding is usually referred to guiding on a single edge of the web material. This is the most common type of web guiding. This method is suitable when the web width does not change during and between runs. Either the operator side or the drive side edge can be guided to the desired location based on the sensor position.



### Center Guiding



Center guiding is a preferred method of guiding when the edges of the web are uneven or if the width of the web changes during or between production runs. Instead of positioning the web based on one edge, the center line of the web is guided. The center position is determined by using two sensors, one on each edge of the web.



### Line Guiding



In certain applications, such as slitting of printed webs, the web may be guided based on the position of a printed line. The line is a fixed reference for the position of the print on the web. Since the position of the print on the web with respect to the web edge may vary between runs, the printed line acts as the fixed reference for guiding the web. Most often a camera based solution is used to guide the web based on the printed line.



### Contrast Guiding



Similar to line guiding, the web may be guided based on a contrasting feature on the web. A printed contrast or a contrast due to a coating process can be used as the reference for web guiding.



### Web Guide Oscillations



Finally, in some applications the web is deliberately made to oscillate back and forth. Most often the oscillations are necessary to prevent any gauge band buildup while rewinding a non-homogeneous web or a composite web or a web with gauge variations along the width. An ideal way to create this oscillation is to guide the web to an oscillation reference. Primitive systems would oscillate the web edge sensor while the web guide moves the web to track the oscillation sensor position. Modern systems can create an oscillating reference digitally.



   

## Finding the Best Web Guiding Equipment for Your Operation



As we search for the most appropriate equipment for our operation, we are faced with the task of selecting from myriad options based on technical data and specs. Through these data, [measurements of accuracy, precision, linearity and resolution](https://r2r.tech/articles/accuracy-precision-linearity-and-resolution-web-guiding-understanding-terminology), manufacturers are trying to present the benefits of their products based on the device’s performance profile. However, sometimes what appears to be the best offer, based on what looks to be the best technical data, might not really be the best. The technical data can even be irrelevant information when considering performance. See [performance indicators](https://r2r.tech/articles/accuracy-precision-linearity-and-resolution-web-guiding-understanding-terminology) relevant to your system and how to apply this information to your applications.  

---

# Web guiding system: Why, What, Where and How?

URL: https://r2r.tech/articles/web-guiding-system-why-what-where-and-how.md

## Why is a web guiding system needed?



Web material transported within converting machines will not always track straight. A [web guiding system](https://r2r.tech/articles/web-guides-or-web-guiding-systems-overview) is required for proper alignment of the material.



A variety of factors such as, poor quality raw materials, material property variations in raw materials, improper machine alignment, improperly maintained machines, environmental conditions, and processing conditions, cause lateral web misalignment as they are transported in the converting machines/lines. Lateral variations due to poor quality of raw material include telescoped rolls, poorly wound rolls with lateral misalignment (see image below), cambered webs, raw material with web thickness variations, etc. Even if the raw materials are perfect, process variations in speed and tension might cause changes in traction that steer the web improperly. Finally, roller misalignment, changes in roller drag and air entrainment between the web and roller can cause lateral misalignment.



> Web materials are not perfect, and neither are converting machines. 

 ![Examples of a telescoped roll, poorly wound roll and well wound roll.](https://r2r.tech/sites/default/files/inline-images/Examples%20of%20incoming%20roll%20issues.png)

Aligning the flexible web material over the rollers (cross machine direction or the lateral direction which is along the width of the material) during transport within the manufacturing process is critical to most converting applications. Often, wastes such as wrinkling, creasing, misregistration (both print and material), and at times web breaks are attributed to web alignment issues during transport. Reducing these wastes improves the productivity of the manufacturing process.



## What is a web guiding system and where is it needed?



Web guiding system is also referred to as [web guides or lateral guides](https://r2r.tech/articles/web-guides-or-web-guiding-systems-overview). These devices are used in aligning the flexible material roll-to-roll converting machines. As the name suggests, the device guides the material to the desired position. Web guides are used in different locations within the manufacturing machines based on the process requirement. Web guides in the intermediate processing areas are called intermediate web guides. Web guides used at the entry or exit of the manufacturing machines are terminal web guides.



[Intermediate web guides](https://r2r.tech/products/narrow-web-steering-guides) are typically used before or after a process where material positioning is required; web guides at the end of a long oven or at the entry of a coating or printing process are common locations for intermediate web guiding. Unwind guides are used to position the material coming off a material roll at a correct location within the machine while a rewind guide is used to wind rolls with good roll edge quality. No matter where the web guide is used, the function of the device is to ensure proper alignment of the material within the machine or on a material roll.



## How does a web guiding system work?



As the flexible material is transported over rollers, the web tends to align itself perpendicular to the axis of rotation of the rollers (see the animation on the right). This is called the normal entry rule and this is the reasons for web misalignment when the rollers in a converting machine are not aligned properly.

 ![Animation showing the normal entry rule.](https://r2r.tech/sites/default/files/inline-images/NormalEntry.gif) ![Animation showing the working of a guide mechanism.](https://r2r.tech/sites/default/files/inline-images/Guiding-Top-View.gif)

Web guides that align the material use the same normal entry principle (see Figure 3). By deliberately changing the axis of rotation of the guide roller, the web guides steer to a different position. Several types of web guides are used to align the web; the difference is in the way the axis of rotation of the roller is changed.



## What are the components of a web guiding system?



Web guides are often electro-mechanical (and for some applications there are electro-pneumatic, or electro-hydraulic or completely pneumatic) devices that automatically control the edge or the centline position of the web within the machine. There are three main components (see Figure 4) of a web guide: (1) [sensor(s)](https://r2r.tech/products/aris-web-position-sensor), (2) [controller](https://r2r.tech/products/scu5-controller), and (3) guide mechanism. The sensor is the vision to the system used to sense the actual/current position of the web material. Different types of sensors are used to measure the lateral position of the web material. The type of sensor is usually based on the type of web material and the processing application. The position information from the sensor is then sent to a [controller](https://r2r.tech/products/scu5-controller) which is the brain to the guiding system. The controller processes the sensor information and determines the required corrective action for the guide mechanism in order to guide the material to the required position. The controller then commands the actuator, which is part of the guide mechanism, to physically steer the web material to the desired location. Typically the controller is an electronic hardware; electrical and pneumatic controllers are seldom seen in practice today.

 ![Components of a web guiding system](https://r2r.tech/sites/default/files/inline-images/web-guiding-system-components_0.png)

The [web guiding system](https://r2r.tech/articles/web-guides-or-web-guiding-systems-overview) is essentially an automatic control device that constantly corrects the position of the web based on the sensor measurement. The effectiveness of this control system is dependent on all the three main components of the guiding system. If any one of the component is faulty the overall guiding system will be ineffective.



## Choosing the Best Web Guiding System for your Operation



As we search for the most appropriate equipment for our operation, we are faced with the task of selecting from myriad options based on technical data and specs. Through these data, [measurements of accuracy, precision, linearity and resolution](https://r2r.tech/articles/accuracy-precision-linearity-and-resolution-web-guiding-understanding-terminology), manufacturers are trying to present the benefits of their products based on the device’s performance profile. However, sometimes what appears to be the best offer, based on what looks to be the best technical data, might not really be the best. The technical data can even be irrelevant information when considering performance. See [performance indicators](https://r2r.tech/articles/accuracy-precision-linearity-and-resolution-web-guiding-understanding-terminology) relevant to your system and how to apply this information to your applications. 

---

# Web Guiding Terminology

URL: https://r2r.tech/articles/web-guiding-terminology.md

Different terms related to web guiding are discussed in this article.



## Web Guiding



Web guiding is the process of regulating the cross machine position of the web while the web is transported over the rollers in roll-to-roll processing machinery. Other terms for web guiding include:



- Steering
- Tracking
- Edge/Line/Contrast Guiding
- Lateral Control
- Lateral Registration
- CD (Cross-machine Direction) Registration
- Lateral Alignment
- EPC (Edge Position Control)
- LPC (Line Position Control)



## Web Guide



The device that is used to automatically control the lateral position of the web in a roll-to-roll or converting machine is called a web guide. The different terms used for a web guide include guider or web guiding system or simply a guide.



Web guide is a term that is used to describe the mechanism or the structure as well as the complete control system. A better term to refer to the complete system is a web guiding system. The web guiding system includes the following four essential components:



- Web guide mechanism
- Sensor
- Controller
- Actuator



### Web Guide Mechanism



This is the mechanical structure that makes contact with the web and positions the web. The web guide mechanism typically translates and/or rotates to position the web. Some other terms for web guide mechanism include, web guide structure or web guide frame. As mentioned above, sometimes the web guide mechanism is referred to as a web guide for short. But this becomes often confusing.



### Sensor



The web guiding system should include a sensor that measures the position of the web. This position measurement is used as the feedback for the web guiding system to guide/position the web to the desired location. Other terms used for the sensor include:



- Web edge sensor or edge sensor
- Web guide sensor
- Web position sensor



### Controller



[Controller](https://r2r.tech/products/roll-2-rollr-controller)is the intelligent part of the web guiding system that enables the automatic control. The controller acquires the web position feedback from the sensor, computes the desired corrective action and commands the actuator (connected to the web guide mechanism) to position the web guide mechanism in order to position the web at the desired location.



### Actuator



[Actuator](https://r2r.tech/products/web-guide-actuators), the muscle of the web guiding system, provides the force or thrust to move the web guide mechanism based on the controller command.



All web guides or web guiding systems have the four key components. Depending on the application each of the four components have different types of their own. This article will mainly focus on the different types of web guide mechanisms and their respective terminology. In subsequent articles we will discuss the different types of sensors, controllers and actuators and their respective terminology.



## Intermediate Guide



Intermediate guide is a term used to refer to a web guide mechanism that is used in the interior part of a roll-to-roll or converting machinery. These guides are shifting the web that passes over them. Typically they are located right before a critical process such as printing, coating, lamination, slitting, etc. There are several types of intermediate web guides including:



- Offset pivot guide (OPG) a.k.a  Displacement guide
- Positive displacement guide
- Pivot frame
- Table guide

  Remotely pivoted guide (RPG) a.k.a

- Steering guide
- Steering roll(er)
- Swivel roll(er)
- End pivoted guide
- Center pivoted guide
- Turnbar



In some cases passive web guides such as crown rollers, spreader rollers and even reel flange are used for guiding the web, This might work for some applications but not a good idea where web guiding is critical.



It is not uncommon to hear people loosely call a guide as a steering guide. Most often they are referring to a web guide, not necessarily the specific type of intermediate guide which is the remotely pivoted guide. Since the different types of intermediate guides have their advantages and disadvantages based on the application, it is necessary to understand the application before a certain type of intermediate web guide is used. The application depends on the locational constraints, guiding performance requirements, type of web used, etc. Please consult one of our experts if you have any questions.



Most intermediate web guides have one or more roller(s) over which the web is transported. The roller(s) is mounted on a movable top structure that is rotated or translated while a fixed bottom structure is mounted rigidly to the machine frame. The web guide mechanism positions the web as it rotates and/or translates.



## Terminal Guide



Terminal guides are located at the entry and exist of roll-to-roll machines and they move the entire roll of web. When the roll of web is fed into a machine or when the roll is wound back into roll, the whole roll will be moved so that the web is fed at the right location and wounded at the right location. Terminal guides have several terms such as:



- Shifting stand
- Shifting base
- Shifting sidelay
- Roll positioning stand
- Unwind guide
- Rewind guide



It has to be noted that these terminal guide are moving the entire roll of web on the unwind or rewind stand. Typically these guides have a movable stand on linear bearings that is positioning the entire unwind or rewind roll at the desired location.



It is common for users to call a web guide as an unwind guide or a rewind guide, just based on where they are located. In fact they may be referring to intermediate web guides that are located at the unwind or rewind section and not necessarily a terminal guide that is moving the entire roll on a stand. Hence it is necessary to understand the terms and use them appropriately, since the two types of web guides function different.



## Lateral Web Dynamics



The physics or dynamics that governs the cross-machine direction behavior of the web as it is transported over the rollers is called the [lateral web dynamics](https://r2r.tech/articles/adaptive-control-web-guides). This web behavior is affected by several parameters such as, the type of web guide mechanism, the installation of the web guide mechanism, web speed, web tension, web thickness, web width, web stiffness or Young’s modulus of the web.



## Entry Span



The web span just preceding the entry roller (or the guide roller if the web guide mechanism has only one roller) of a web guide mechanism is called the entry span. For intermediate web guides the entry span play an important role since the span could affect the lateral web dynamics.



## Exit Span



The span just succeeding the exit roller (or the guide roller) of a web guide mechanism is called the exit span. Exit span also plays an important role for intermediate web guides since they could affect the lateral web dynamics.



## Guide Span



When a web guide mechanism has more than one roller, the span within the web guide mechanism is called as the guide span. For some intermediate web guides, the length of the guide span is a design parameter that is influenced by the application.



## Edge Guiding



When the edge position of the web is used for guiding it is called edge guiding. For a variety of applications edge guiding may be sufficient especially if the roll-to-roll machine is designed to convert a constant width web all the time. Typically a web edge sensor is located in the downstream span of a web guide (except with a rewind guide). Typically the web edge is sensed in the free span and not on a roller. Several types of edge sensors based on different sensing principles are available in the market. These include pneumatic web edge sensors, ultrasonic web edge sensors, infrared web edge sensors, optical web edge sensors, camera based web edge sensors and fiber optic web edge sensors. The different sensor technologies have their advantages and disadvantages.



## Center Guiding



When webs with different widths are processed within a single converting machine, it is often common to have the processes centered with respect to the machine. In those scenarios the web would also need to be guided to the middle of the machine irrespective of its width. This can be achieved by guiding the centerline position of the web, instead of one edge of the web; this is called center guiding. Center guiding can be achieved by measuring the position of both edges of the web using one or more sensors. The average position of the two edges would correspond to the center line position of the web. This measurement is used as feedback by the web guiding system to position the web appropriately.



## Line Guiding



Mostly in printing and subsequent converting applications, it may be necessary to guide the web based on the position of a printed line instead of the edge (or the centerline position of the web). This is because the printed pattern on the web may not always be at the same distance from the edge of the web on every roll. If in the subsequent process the web alignment with respect to the printed pattern is critical then it may not be appropriate to guide the web based on the edge position or the centerline web position. In line guiding applications, apart from the print pattern for the web, a line is typically printed close to the edge of the web which is subsequently used for guiding the web in a downstream locations.



## Contrast Guiding



Similar to line guiding, contrast guiding involves guiding the web based on a contrasting feature on the web instead of the edge or the centerline position. The main difference between the line and contrast guiding is that a line is not explicitly printed just for guiding purpose; rather an existing repeated pattern or a contrasting feature on the web is used for guiding purpose. The feature may be edge of a print or edge of a coating or edge of a pattern such as a barcode.



## Wrap Angle



When the web is threaded over a roller, the angle (in degrees) the web makes contact with the circumference of the roller is called the wrap angle. Wrap angle is an important aspect of web handling and web guiding, Wrap angle affects traction and thereby web guiding since without traction the web cannot be guided properly.



## Backup roller



When a contrast feature or a line on the web is used for guiding, it is typical to use camera based sensor or optical sensor to detect the contrast/line. When a contrast or line sensor is used, it is necessary to support the web to provide a stable image for the optical/camera sensor. A roller is used to support the web by wrapping the web around this roller. This support roller is called a backup roller. Typically the angle of wrap with the backup roller is small so that the roller does not significantly influence the lateral web dynamic due to that backup roller.



## Plane Change or Web Pass Line Variation



When a web guide structure rotates or translates, the plane of the web in the span immediately downstream of the guide roller may change. The exit span may twist or bend the web which causes the plan to change. This plane change is also called the pass line variation. Depending on the magnitude of the rotation or translation, the plane may change significantly. Some sensors might be affected by the plane change or pass line variation.



## Normal Entry Rule



Web approaching a roller will align itself perpendicular to the axis of rotation of the roller, this is called the normal entry rule. Most web guide mechanisms take advantage of this fundamental principle to position the web. Most intermediate web guides have a mechanism to enable the guide structure to rotate so that the axis of rotation of the guide roller(s) are changed thereby guiding the web.



## Pivot Point



The web guide mechanism that rotates typically have a physical pivot point around which the mechanism rotates. Pivot point is typically present in intermediate web guides such as offset-pivot web guide (or displacement web guide) or end pivoted web guides.



## Virtual Pivot or Instant Center



For certain web guide mechanism a physical pivot point may be absent. Virtual pivot point is the point around which the web guide mechanism rotates or the virtual center of rotation of the mechanism. Virtual pivot points are common with steering guides, center pivoted web guides and certain displacement or offset-pivot web guides. For steering web guides the virtual pivot point is also called as the instant center.



## Turnbar Web Guides



Turn bar is a device that twists the web and changes the web path and the plane of the web, often about 90° with each twist. As the name suggests turn bars are fixed cylindrical bar and do not rotate. For certain application, turn bars are actuated to guide the web and such devices are called as turnbar web guides.



## Plane of Motion



Plane of motion of the web guide is the plane in which the guide mechanism rotates or translates. For most web guiding system installation the plane of motion is not critical. However, for steering guides plane of motion is an important installation parameter. It is recommended that the exit span is at an angle of 90° for the best web guiding performance.



In the subsequent articles we will dive into more details about web guiding addressing several of the topics in much more rigor.

---

# Web Handling Terminology

URL: https://r2r.tech/articles/web-handling-terminology.md

## Web



Web is a material that is thin, flexible and continuous in nature. Web materials are transported within a machinery to convert them into finished products. A wide variety of consumer products are made from web materials such as paper, plastics, films, foils and metals, into finished products such as diapers, female hygiene products, labels, tapes, magazines, aluminum cans, and even some electronics.



## Web Handling



Web handling is the process of controlling and transporting the web within the process machinery with the goal of minimizing the defects due to the transport.



## Converting



Converting is the process of transforming the web from its continuous flexible form, into another permanent form. Some examples of converting processes include, printing, coating and lamination where the raw web is converted into finished products.



## Roll-to-Roll Processing



Since the term “web” is often confused with the “World Wide Web” the terms “Roll-to-Roll’ is becoming predominant. Roll-to-Roll processing is synonymous to converting or web processing where the term is derived from the fact that the web materials goes from a roll to another roll.



## Rolls



When the flexible web is wound on a core of material it is called a roll of web or wound roll.



## Rollers



Rollers are part of the processing machinery that support the web while they are transported within the machinery. The rollers may be made from materials such as steel, stainless steel, aluminum or carbon fiber.



## Idler Rollers



Some rollers are intended only for support and these types of rollers are called idle rollers or idler rollers. These rollers have low friction bearings that allow them to spin at the same speed as the web.



## Dead Shaft Rollers



Some of the idler rollers might have a dead shaft with bearings supporting the spinning outer roller surface. The dead shaft is fixed to the machine frame and the outer shell spins while the shaft is stationary. These rollers are most common for application where the roller function is purely for support of the web.



## Live Shaft Rollers



Live shaft rollers have the shaft and the outer roller surface rigidly connected while the whole assembly is supported on bearing mounted on the machine frame. Both the shaft and the shell rotates. Live shaft rollers are common with driven rollers, heating and cooling rollers and other process rollers.



## Driven Rollers



These are usually live shaft rollers, that are connected to a torquing device such as a motor, to transfer the torque or force to the web.



## Web Span or Free Span



The unsupported portion of the web between two rollers is called a web span or a free span or simply a span.



## Span Length



The length of the unsupported portion of the web between two rollers is the span length.



## Web Speed or Transport Velocity



The speed at which the web is transported within a processing machinery is called the web speed or transport velocity. The web speed is usually expressed in feet-per-minute (fpm) or meters-per-minute (mpm). The web speed is typically measured or inferred from the driven rollers.



## Machine Direction or Transport Direction



Machine direction (MD) is the direction in which the web is transported. This is also along the length of the web. Web speed and web tension are measured along the machine direction.



## Web Tension The force in the web or the force applied to the web in the machine direction is called the web tension. The unit of tension is pound (lb) or Kilogram (Kg). It is also common to express this force normalized with respect to the width of the web as pounds-per-linear-inch (PLI). Longitudinal Control



The machine direction control of web speed and web tension is called longitudinal control. This is an integral part of web handling. Good longitudinal control can increase the efficiency of the overall machine by increasing the web transport speed while delivering the web with minimum defects through the process machinery.



## Tension Control



Tension control involves the active control or regulation of tension within the processing machinery using a closed loop control system. Tension is controlled by either speeding up or slowing down two rollers (using driven rollers or breaks) or by directly applying a tensile force with a mechanism such as a dancer. A force feedback device such as a load cell may also be used to close the loop.



## Draw Control



The open loop control of tension by maintaining predefined velocity ratios between driven rollers is called draw control.



## Dancer



A device that is typically made of one or more free moving idle roller(s) that imparts force on the web. Dancer rollers may have linear motion or rotary motion (with a pivot arm) to move or change the span length upstream and downstream of the dancer roller.



## Load Cell



A transducer, typically made of strain gauges, that is used to measure the tension force on the web.



## Tension Zone



The spans or regions of the machine where the tension is regulated or controlled is called a tension zone. Roll-to-roll processing machinery might have multiple tension zones that are controlled by multiple tension control systems. Driven rollers and brakes (to slow the web down) are typically used to control tension based on tension measurement from transducers.



## Nip Roller(s)



Nip is usually a rubber covered roller or a roller with a flexible surface that is used to squeeze the web onto another roller. The nip roller(s) apply force on the web for various reasons. Processes such as lamination, embossing and printing may need the force applied by the nip for the converting process. Nips are also used to increase friction between the web and the roller and for isolating tension zones in general web handling applications.



## Traction



Traction is the adhesive friction force between the web and a roller. High traction implies a high friction force or grip between them. When there is enough traction between the web and the roller, the surface velocity of the roller and the linear web speed will be the same. Web traction can be increased by increasing the coefficient of friction (COF) of the web surface, the COF of the roller surface, increasing the web tension or by increasing the nip pressure.



## Web Slip



When there is not enough traction between the web and the roller, the web speed may be more or less than the surface velocity of the roller; the web slips on the roller. When the web slips on the roller the web is sliding on the roller surface thereby having a relative velocity between the web and the roller surface. When there is enough traction, the web grips the roller and thus have zero relative velocity between the two.



## Air Entrainment



The phenomenon of air trapping between the web and a roller as soon as the web (or the roller) starts moving is called air entrainment. Depending on the surface roughness of the roller, the surface roughness of the web, the web speed and the porosity of the web material, the increase in speed of the roller rotation can increase the volume of air entrained between the two surfaces. This entrained air acts as a lubricant and reduces the traction between the web and the roller.



## Cross Machine Direction



Cross machine direction is perpendicular to the machine direction and parallel to the width of the web.



## Web Guiding



Web guiding is the process of regulating the cross machine position of the web while the web is transported. Other terms for web guiding include lateral control or lateral alignment or CD alignment or lateral registration or CD registration.



## Web Guide



The device used to control the lateral position of the web is called a web guide or simply a guide.



In the next article we discuss more terminologies specific to web guiding.

---

# Web Position Sensor Overview

URL: https://r2r.tech/articles/web-position-sensor-overview.md

> Controlling the web requires accurate and precise web position measurement. In inaccuracies in the sensor measurement leads to increased waste and downtime.



## Existing Sensors and Sensing Principle



Opposing mode or through beam sensing mode sensors are the most common sensors used for web edge detection. These U-shaped or fork-shaped sensors have one arm to transmit the sensing signal while a pre-aligned receiving arm collects the transmitted signal. The web material that is passed between the two sensor arms blocks the signal and the receiver arm collects the portion of the signal unblocked. In ideal cases the amount of signal received is proportional to the percentage of the signal blocked by the web material, thereby the web position can be inferred.



The signal used in this sensing principle may be light (visible or infrared), sound (ultrasonic) or air (pneumatic). Often the choice of sensor used for a particular application depends on the material. The material dependent property of the sensor is the main drawback of this simple sensing principle. Whenever a particular material allows a portion of the signal to pass through the web material the sensor accuracy is affected. As illustrated below both slope and bias (linearity) of the sensor output is affected by materials that transmit the sensor signal. To compensate for this error the sensor needs to be calibrated to improve the accuracy of the output. However, with certain materials no amount of calibration may lead to a satisfactory output for the type of sensing signal.

 ![Conventional edge detection sensor technology based on blocking and unblocking](https://r2r.tech/sites/default/files/inline-images/Covention-edge-detection-sensor-technology.png)

## Roll-2-Roll Technologies Web Position Sensor Working Principle

 ![Light scattering principle used in ARIS web position sensor](https://r2r.tech/sites/default/files/inline-images/light-scattering-principle-used-in-ARIS-wps.png)![Spatial filtering principle used in ARIS web position sensor](https://r2r.tech/sites/default/files/inline-images/Spatial-filtering-principle-used-in-ARIS-wps.png)

### Scattering



Any material opaque, transparent, translucent, porous or nonwoven material will scatter light incident on them. The amount of scattering depends on the material properties such as roughness of the material, wavelength of incident light, refractive index (for transparent material), among other properties. [Roll-2-Roll Technologies WPS](https://r2r.tech/products/aris-web-position-sensor) relies on the property that some amount of light will be scattered by any material. A light source, such as laser or LED is used to illuminate the area near the edge of the web. As the light falls on the web, the light is scattered in all directions. By collecting the light scattered from the web material the position of the web edge is determined.



### Spatial Filtering



The light transmitting properties of the optical fibers is enabled by the principle of total internal reflection. The total internal reflection occurs due to the change in refractive index of the core and cladding within the optical fibers. This property of the optical fibers also result in the fibers acting as spatial filters.



Roll-2-Roll Technologies WPS uses the spatial filtering properties of fiber optics to filter the scattered light from the web surface. Since the fiber optic array is directionally sensitive, light is spatially filtered in a way that only fiber(s) directly inline with the scattered light are illuminated. All other fibers do not couple light since the scattered light falls on them at an angle greater than the critical angle. The spatially filtered light is projected onto a one dimensional line scan camera and the image recorded by the camera is processed using advanced digital signal processing algorithms to accurately detect the position of the material.



Any material, such as opaque, transparent, porous or nonporous, scatters (or reflects) light. Therefore, the sensor is not affected by the material properties. The intelligent digital signal processing automatically adapts to any changes in the amount of scattering to provide a true, absolute measurement.



## Comparison of Roll-2-Roll Technologies Web Position Sensor and other sensing technologies



### Advantages of Roll-2-Roll® Sensor sensing principle



The sensing principle is unaffected by the material properties. This enables the sensor to require no setup or calibration. Additionally, by changing the wavelength and the angle of the incident light, the position of a contrasting feature on the web such as a colored line can be detected.



| Sensor Characteristics | Roll-2-Roll WPS | U-Shaped Infrared | U-Shaped Ultrasonic | U-Shaped Pneumatic | Camera or Vision System |
| ---------------------- | --------------- | ----------------- | ------------------- | ------------------ | ----------------------- |
| Unaffected by Opacity | ✔ | ✘ | ✔ | ✔ | ✘ |
| Unaffected by Porosity | ✔ | ✔ | ✘ | ✘ | ✔ |
| Unaffected by Splices | ✔ | ✘ | ✘ | ✘ | ✔ |
| Unaffected by Dust | ✔* | ✘ | ✘ | ✔ | ✘ |
| Unaffected by Temperature Change | ✔ | ✔ | ✘ | ✔ | ✔ |
| Unaffected by Vacuum | ✔ | ✔ | ✘ | ✘ | ✔ |
| Unaffected by Ambient Light | ✔ | ✔ | ✔ | ✔ | ✘ |
| Unaffected by Vibration or Ringing | ✔ | ✔ | ✘ | ✔ | ✔ |
| Analog or Digital Measurement | Digital | Analog | Analog | Analog | Digital |
| Line Detection | ✔ | ✘ | ✘ | ✘ | ✔ |
| Contrast Detection | ✔ | ✘ | ✘ | ✘ | ✔ |
| Resolution Unaffected by Range | ✔ | ✘ | ✘ | ✘ | ✘ |
| Automatic Calibration | ✔ | ✘ | ✘ | ✘ | ✘ |



* The dust issue can be reduced by using intelligent digital processing algorithms.



As we search for the most appropriate equipment for our operation, we are faced with the task of selecting from myriad options based on technical data and specs. Through these data, [measurements of accuracy, precision, linearity and resolution](https://r2r.tech/articles/accuracy-precision-linearity-and-resolution-web-guiding-understanding-terminology), manufacturers are trying to present the benefits of their products based on the device’s performance profile. However, sometimes what appears to be the best offer, based on what looks to be the best technical data, might not really be the best. The technical data can even be irrelevant information when considering performance. See [performance indicators](https://r2r.tech/articles/accuracy-precision-linearity-and-resolution-web-guiding-understanding-terminology) relevant to your system and how to apply this information to your applications. 

---

# Web Width Measurement and Monitoring:  Applications and Technology

URL: https://r2r.tech/articles/web-width-measurement.md

## Web Width Measurement and Monitoring



Measuring the width of the web (or the cross-machine dimension of the web) is essential for various converting applications. Web width measurement is crucial for quality control and web handling purposes. Some examples of converting processes requiring width measurement include:



- Slitting
- Folding applications, such as shrink sleeve manufacturing
- Sheet and film extrusion
- Textile, tire and rubber manufacturing
- Coating and lamination



Effective cross-machine dimension control (web width and web position control) can significantly reduce waste in the process, directly contributing to the bottom line. In this article, we will examine web width measurement and control in detail.



### Width Measurement and Monitoring for Slitting Applications



![Example of web width measurement for slitting applications](https://r2r.tech/sites/default/files/inline-images/Slitter%20Rewinder%20Small.jpg) Slitting is the process in which a single wide web from a jumbo roll is slit or cut into narrower webs. Depending on the material, several types of slitting mechanisms include:



- Razor slitting
- Score slitting
- Shear slitting
- Band and blade



Automated or manual blade positioners may be used to position the blades along the cross-machine direction of the web to cut the lanes along the machine direction. With manual blade positioning, operators align the blades at the desired cross-machine position. To assist with proper blade positioning, rulers on the machine or even laser pointers may be used. Some older machines might require measuring tape to measure blade positions. All of these methods have potential for errors in blade positions, which could cause errors in the slit width of the web material.



Current state-of-the-art slitters might include automated blade positioners to reduce operator errors. Even when the slitting blade positions are set accurately, the final web width can differ from the desired web width. This discrepancy may result from tension variations, shear forces, or stresses in the web creating variations dependent on the type of material and the slitting process.



Some common applications for width measurement in slitting include:



- Tape slitting
- Film and foil slitting
- Printed flexible packaging material slitting
- Label slitting
- Flat ribbon cable slitting
- Lithium-ion battery (anode and cathode) slitting
- Paper slitting
- Hook and loop fastener slitting



Width measurement and monitoring are used to ensure that slitter blade position errors or process variations are detected on time and before the product reaches the end customer. Width tolerances for slitting usually range from ± 5 mm to ± 0.1 mm, depending on the application. Small error tolerances are harder to detect with manual visual inspection by operators, making some applications require real-time width measurement and monitoring instrumentation.



### Width Measurement and Monitoring for Folding Applications



![Web folding application where the web is entering a forming frame](https://r2r.tech/sites/default/files/inline-images/Fixed%20Folding%20Small.jpg)Folding is a common converting process in which a layer of web is folded into multiple layers. Folding processes are typical in diaper manufacturing, tissue paper manufacturing, and shrink sleeve manufacturing.



Measuring the width of the web after the folding process is a critical quality control metric. Some folding defects may be cosmetic, while others may be functional. For example, a few millimeters' difference in napkin folding might create a cosmetic defect. However, a similar difference in shrink sleeve manufacturing may make the product too tight to fit or too loose to shrink properly. Similarly, in diaper manufacturing, the folding defect might cause glue buildup that can lead to machine stoppages over time.



The centerline position of the web and the folder geometry dictate the final web width in these applications. For example, if the centerline position of the web is offset from the folder, the final width of the folded web would be affected. Typically, a web guide (in center guiding mode) is used before a folder to ensure that the web enters the folder at the correct location to produce the desired folded web width.



An additional level of complexity is introduced in folding applications when the web width changes, or the folder geometry or position shifts. This is the case for shrink sleeve seamer applications. The seam position in a shrink sleeve application depends on the cosmetic appearance of the end product, altering the folder location with respect to the centerline position of the web. Web width changes are also common in shrink sleeve converting machines since the converter may handle a wide variety of end products within the same machine. Therefore, proper width measurement, control, and monitoring are crucial for shrink sleeve converting applications.

 ![Shrink sleeve web width measurement application](https://r2r.tech/sites/default/files/inline-images/Shrink-Sleeve-Width.jpg)

In shrink sleeve manufacturing, the width tolerance of the sleeve may range from ± 0.25mm to ± 1mm to ensure that the sleeve is neither too big nor too small for the end application. Most often, the lower limit of tolerance is 0 mm, while the upper limit is +0.5mm, guaranteeing that the sleeve is never too small to slide onto the package it will cover.



One additional challenge with shrink sleeve width measurement concerns the dimensional measurement itself. While forming and sealing the sleeve, some air is entrained within it, altering the product's dimensional width due to out-of-plane web deformation. If the shrink sleeve lacks a hard crease, the two folded edges have a radius, which also changes the projected width of the sleeve seen by the width measurement system. When the measurement tolerance is within a fraction of a millimeter, this effect is significant.



### Width Measurement and Monitoring for Plastic Sheet and Film Extrusion



Width measurement and control are vital in plastic manufacturing, such as cast film, blown film, and plastic sheet extrusion. In cast film, the width is primarily determined by the die dimensions and does not change significantly during the run. However, in a blown film line, the layflat width of the final product depends on the process parameters and thus requires control. Finally, in thicker sheet extrusion processes, the final sheet's width depends on the draw, temperature, and viscosity of the molten plastic. Consequently, width measurement and control are not as critical in cast films compared to blown films and sheet extrusion.



![Blown film web width measurement application](https://r2r.tech/sites/default/files/inline-images/Complete%20Blown%20Film%20Line%20Small.jpg)In a blown film line, the layflat width of the material relies on the overall bubble dimension, which may or may not be automatically controlled. Some blown film lines feature active internal bubble cooling (IBC) to maintain the bubble dimension throughout the production run by cooling the air inside the bubble. The bubble dimension is actively controlled by managing the inlet and exhaust airflow based on the bubble dimension. Without IBC, an operator may need to monitor the bubble dimension to maintain a certain layflat width. In some cases, the layflat width might be measured before the winder with a non-contact width measurement system, which can also be used to actively control the bubble width. One advantage of measuring the layflat width close to the rewinder is that the film will have undergone cooling or might have shrunk to the final product size. A disadvantage of controlling bubble size based on layflat width measurement is the significant delay in the control action; any airflow change at the extruder die will not immediately result in width change feedback, which also depends on the web transport speed. Thus, it is a challenging control problem.



Measuring and controlling the layflat width in the blown film process is essential to reduce waste and ensure quality. Width, being an important quality metric, makes it not uncommon for rolls or truckloads of well-wound rolls to be rejected due to not meeting the customer's width specifications.



Typically, the width tolerances for these applications range from ± 1 mm to ± 10 mm. These tolerances are relatively high compared to other applications, but it is difficult for operators to notice even 25 or 50 mm of width change over a 2.5 m wide roll. It is also impractical for operators to measure the width of the wound roll manually due to safety reasons. Moreover, intentional oscillations to prevent gauge band buildup might also make manual width measurement challenging.



Proper width control can save a significant amount of trim waste while slitting the edges. Although the trims can be recycled, trimming more material than needed results in considerable monetary loss. Improving cross-machine direction dimensional control could directly contribute to the bottom line.



In the plastic sheet extrusion process, the product width is also affected by process parameters such as draw speed, plastic extrusion temperature, and viscosity. Therefore, measuring and monitoring the width of the extruded sheet is crucial to reduce waste and improve process efficiency.



### Width Measurement and Monitoring in Textile, Tire and Rubber Industry



![Web width measurement and monitoring in textile industry](https://r2r.tech/sites/default/files/inline-images/Textile%20Manufacturing%20Small.jpg)Width measurement is critical in applications where the web material is heated and cooled to create the required material properties. For example, in textile manufacturing, the fabric may undergo special coating or dyeing involving heating and cooling. This process can cause the material to expand and contract in the cross-machine direction, depending on the material properties. Hence, measuring the width of the web before and after the thermodynamic processes is necessary to ensure quality.



Similarly, in tire and rubber applications, width is a critical factor for a quality finished product. The measurement occurs during the calendering process, where rubber compounds are flattened and spread into a thin sheet of uniform thickness. The web width measurement is performed by passing the sheet through a measuring device that detects the sheet's edges and calculates the width. The width is also measured during the tire-building process, where the sheet of rubber is cut and wrapped around a tire-building drum to form the tire. The web width measurement ensures that the cut sheet has the correct dimensions and is wrapped evenly around the drum.![Web width measurement application in tire and rubber industry](https://r2r.tech/sites/default/files/inline-images/Tire%20Manufacturing%20Small.jpg)



### Width Measurement and Monitoring in Coating Applications



Width measurement is essential in coating applications to ensure that the coating material is applied evenly and uniformly across the web surface, without gaps or overlaps. Coating width measurement helps monitor and control the coating process, ensuring that the desired coating width is achieved. Width measurement is also important for controlling the position of the coating apparatus. If the coating is applied off-center or outside the desired width range, it may cause issues with downstream processes such as printing, lamination, or slitting.



### Width Measurement and Monitoring in Converting Applications



Besides measuring width for quality control, width measurement is also vital for web handling. One of the main reasons for changes in web width is variations in tension throughout the converting machine. When tension is applied to a web, it can cause the web to stretch or compress, leading to changes in the web width. This is especially prominent with low basis weight materials, such as nonwovens. Since tension is seldom controlled in these machines (low basis weight nonwoven converting machines), monitoring web width is critical to ensure good web handling.



Other factors that can cause changes in web width include variations in temperature, humidity, and pressure. For example, heating and cooling in the embossing process can expand and contract the web, potentially causing web width changes that result in cosmetic quality problems.



## Methods of Measuring Web Width



### Manual Measurement



![](https://lh4.googleusercontent.com/JUkF1Itd9K8oj5NK1j9wHD9Z6d-kDXtBt2dft7sZCOwBl5xXrEzXOUROd1IBR5A05Z4KN7Uu-lsB-HQrH479GgwFpEbPwPpMov3DAtgkU_7THHGcSCE87k0GONz7uf-DgAendB8F8DAIvKVKr81ZVbw)Offline manual width measurements by operators are common in some applications. These measurements are typically taken using calipers, rulers, or tape measures by the operators as part of their standard operating procedures. These simple and inexpensive methods are commonly used in low-value products. However, they are prone to both systematic errors and operator errors. In safety-conscious processes, manual measurements by operators are taken while the machine is stopped or by taking a product sample for measurement. In certain cases, especially with wide webs, a single operator might not be able to measure the entire web. The probability of making an erroneous measurement is high in those cases.



In some other cases, sampled web width measurements are also done using desktop lasers or microscopes at quality control labs. Overall, offline measurements are time-consuming and do not provide real-time width information that may be necessary for gaining better insight into the overall quality of production processes. Most importantly, manual web width measurement in the vicinity of the machine while it is running poses safety challenges.



#### Pros:



- Simple
- Inexpensive



#### Cons:



- Prone to measurement errors (systematic and operator)
- Time-consuming
- May require the machine to be stopped while taking measurements
- Can be a safety issue if the measurements are taken while the machine is running
- Measurements might be a sample of the production run without meaningful insights
- Cannot be readily available for IT systems



### Real-time Measurements with Edge Sensors



![](https://lh3.googleusercontent.com/WP-Q4ELPVB4N_V1uu6Fie7uCmR9jtUb1Huq6lE9_hXSiNnH9FVMU_WcQ9TMkwtGxF8he28HyT5meC07FriOiPYGvI2r_7eIZJvCS8DcT8oNn2RWV8XNv_NvMNP9L3eMfoCIlfDV_6AsO_Y_CIsNEVso)Edge sensors (ultrasonic, laser, or photoelectric) can be used to track the web edge position with a resolution of 0.005" or 0.0635 mm. The edge position measurement from the two edge sensors can then be used to measure the width variation in the web. Depending on the sensor technology and the type of material, an appropriate choice of edge sensors may be necessary. For example, ultrasonic sensors and some photoelectric sensors are not ideal for measuring web width of low basis weight nonwoven. Similarly, photoelectric sensors also have issues with clear films.



Width measurement with edge sensors is simple; they can provide accurate measurements with the right combination of material and sensing technology. For high precision and high-resolution applications, even laser micrometers are used for web width measurement. The absolute width of the web can be determined by knowing the distance between the two sensors and by tracking the edge position variation from the respective sensors.



Depending on the type of measurement system, the data from the sensors can be recorded in real-time using a PLC or a data historian system.



One common issue with this type of measurement is that the web edge should be within the field of view of the respective edge sensor. If the field of view of the sensor is small, then the web needs to be guided to the sensor position to get an accurate measurement. Without proper web guiding, excessive web wander may saturate the measurement, resulting in poor accuracy. Moreover, if the product width changes from one production run to another, the sensors need to be repositioned appropriately.



To overcome this limitation, some systems have complex mechanisms with motorized sensor positioners that can be moved to different cross-machine locations to accommodate product width changes. Some sensor positioners may even have automated control systems that keep track of the web edge position and automatically move to a new location based on the movement in the edge position. These fully automated systems allow for web width change without operator involvement and avoid manual sensor repositioning errors. However, they are complex, expensive, and prone to breakdown due to constant wear and tear.



#### Pros:



- High degree of accuracy
- Real-time measurement that can provide meaningful insight into the production process
- Can be used for real-time feedback control of web width
- Increases operator safety



#### Cons:



- Field of view of the sensor should be wider than the web wander
- Web width change requires sensor repositioning
- Can only measure the width of the web and not a coating width or feature width
- Motorized sensor positioners may become expensive depending on the web width change
- Automated motorized sensor positioners are complex and prone to wear and tear issues



### Real-time Measurements with Wide Band Edge Sensors



![](https://lh4.googleusercontent.com/aQ0zGyONtr3LYaTLCgpsopx2SvCTMzgG35ljQfRPkOTJfkynaOxptpnMBZ-p1jM3iiQ3XgrG9F7-sNh9-znDQkiFBzktF2kOd_t8ioH5Qve34q_ehuMMc1t-nhxlm0EOuN-T36XmHat68zJ5kjWTPNA)To eliminate the complexities associated with motorized sensor positioners, wide band edge sensors can be used. If the field of view of the edge sensor is wide enough to accommodate any web width change within the machine, the edge sensors need not be repositioned when the product width changes. This eliminates the complexities related to motorized sensor repositioners.



Wide band (or array) edge sensors can also measure the width of the web with a single sensor if the web is narrow compared to the sensor's field of view. Some sensors can even measure multiple web widths with the same sensor, as long as there is a gap between the webs. This can be achieved with specialized firmware and customization on the sensor. However, one of the biggest drawbacks of edge sensor-based width measurement is their inability to measure the width of a feature (or features) on the web.



![](https://lh5.googleusercontent.com/1fodfS2OC8rePG5J8uhI18ClBN26IdjxWP3eNxfTD3rd3fq9bDuUVumR3in_tPAaidz2ORF4FEkZEXTKbJZqYk8Zy6-8eRgSG2MFoCvgIb_Z1NK7J1sC3A22YwFrfl90L8sxS3xCP5QhchUsXg106HA)



#### Pros:



- High degree of accuracy
- Real-time measurement that can provide meaningful insight on the production process
- Can be used for real-time feedback control of web width
- Increases operator safety
- Web width change does not require sensor repositioning
- Eliminates complexities and issues with motorized sensor positioners
- Higher reliability and overall life of the system
- Allows for instantaneous width changes that might otherwise be difficult with motorized sensor positioners



#### Cons:



- May be expensive compared to small edge sensors, but comparable to a motorized solution
- May require calibration with some web edge sensors based on the material being measured
- Can only measure the width of the web and not a coating width or feature width
- Has issues with more than four webs and if the distance between them is too close



### Real-time Measurements with Camera-Based Machine Vision Systems



The most advanced width measurement systems are camera-based vision systems. These systems typically have a light source, optics, and a camera to capture an image of the web to determine its width. The image captured by the camera-based system may cover the entire width of the web or just regions of the web around the edge. The captured image is then processed using computer hardware (industrial PC or single-board computers), and a corresponding output is sent to a PLC for display or recording purposes. Some systems may be standalone with a digital readout or with alarm outputs.

 ![](https://lh4.googleusercontent.com/SCyMSUbJbRRz0tPWWkucVZe7hVLwqLvCIIsRhX0QBMDFgLaoma9cHZdyyychs5EFMcjuvx5lGxFLbw-dP9gM35KPeVUA8rdlul1WM1dseK9nGtLAuJFVZhZyE_T8QxRJF3BMsuVReiHLyMvb5w7V4rA)


 Depending on the type of the converting process, it may be necessary to measure the width based on a contrasting feature on the web. For example, in label converting, it may be necessary to measure the width (or the gap) of the release liner from the edge of the liner to the edge of the label. Or in a coated web, it may be necessary to measure the width of the coating and not necessarily the width of the substrate. Or in battery applications, it may be necessary to measure the tab width, trim width, and total width all at the same time.



The main advantage of camera-based systems is that they can detect features on the web and use them for width measurement; for example, camera-based systems can detect the width of coatings, gaps between webs, cross-machine distance of a feature from the edge of the web, etc. These systems can also be programmed to measure multiple web widths. However, a camera-based system could become expensive due to the various components needed for the system.



#### Pros:



- Can be programmed to measure the width of features on the web, such as coating width
- High degree of accuracy
- Real-time measurement that can provide meaningful insight on the production process
- Can be used for real-time feedback control of web width
- Increases operator safety
- Web width change does not require sensor repositioning
- Eliminates complexities and issues with motorized sensor positioners
- Higher reliability and overall life of the system
- Allows for instantaneous width changes that might otherwise be difficult with motorized sensor positioners



#### Cons:



- Expensive due to the various components needed
- Light source changes can affect the performance of the system
- A machine vision "expert" is needed to troubleshoot any issues with the system
- Calibration might be complex and typically not done by an operator
- Complex and not user/operator friendly



## Width Measurement Output



Irrespective of the method used for width measurement, the output from the automated measurement has different options. It is common for the automated system to provide a raw output value that is proportional to the physical width of the material. This value is then used to compute the actual width, display the width for the operators, or take corrective action based on the measurement. This output could be an analog output (voltage or current) or a digital value.



### Analog Output



The analog width measurement output could be a voltage or current value. Common output voltage ranges from ±10 V, ±5V, 0-10 V, or 0-5V, while the common current ranges from 4-20 mA, 0-10 mA, 0-20 mA, 4-24 mA, or 0-24 mA.



Based on the measuring system, the sensing range, and the resolution, the analog output value would have an appropriate scale (and bias) that converts the analog output value into physical units. For example, when two edge sensors are used for web width measurement, the individual measurements from the two sensors can be added and provided as an output. This value will be proportional to the portion of the web detected by the respective sensor. The bias or an offset is added to this output based on the distance between the two sensors to determine the overall web width.



Analog outputs are still common even with digital measuring systems where the computation is done using a microprocessor or a microcontroller, while the output is provided in an analog form. This is available to ensure that the width measurement systems can integrate with legacy systems for collecting the measurement data.



The main problem with analog output is that the resolution and the range of the sensor measurement are interdependent and constrained. For example, the minimal resolution for a sensing system with a 100 mm range would be 10x worse than a sensing system with a 10 mm range if the voltage output range for either system is identical. Additionally, the overall resolution of the measurement is the smallest resolution of the digital-to-analog converter (DAC) in the sensor and the analog-to-digital converter (ADC) in the data acquisition system (PLC or industrial computer). For example, if the sensor range is 1000 mm with the resolution of the DAC on the sensor being 12-bit but the resolution of the ADC is only 10-bit, the overall resolution of the measurement is 0.97 mm (= 1000 / 1024). Finally, the electrical noise level in the system also affects the accuracy of the measurement.



#### Pros:



- Simple to integrate and use
- Cost-effective solution
- Fast feedback with minimal overhead



#### Cons:



- Electrical noise could affect the accuracy of the measurement
- Does not provide any additional information (such as signal quality, etc.)
- Multiple analog channels are necessary for multiple width measurements



### Digital Output



Digital outputs, on the other hand, can provide integer (or floating-point) values. With such a measurement, the sensor range and resolution need not be constrained. The measured output can be transmitted to the receiving circuitry using industrial communication protocols that rely on transmission of the data in the form of bits. Digital transmission is not susceptible to noise in the transmission circuitry; however, it may require special cables depending on the protocol. One additional constraint with digital transmission is network congestion or network delay that may affect the rate at which the measurement is transmitted. This is especially relevant for applications that require high-speed feedback for control purposes.



There are no current standards for digital output for width measurement applications. The data may be transmitted over different fieldbus or network-based physical protocols such as CAN, RS485, Profibus, ControlNet, EtherNet/IP, PROFINET, EtherCAT, CC-Link IE, or Modbus/TCP, etc. Data formats may also vary widely based on the vendor.



#### Pros:



- Reliable transmission without noise of the data from the sensor to the PLC
- Multiple web width measurements can be provided with the same connection
- Can provide additional information apart from the width measurement
- Can also allow for remote configuration of the sensor for increased automation
- Can be readily connected to the industrial internet of things (IIoT) for data insights



#### Cons:



- Higher overhead for integration and requires programming skills for integration
- No standard across different vendors in terms of measurement output and fieldbus technology



## Width Monitoring



Instead of just providing a width measurement output, web width monitoring systems go a step further and provide an alarm or an output signal, which is a pass or fail signal (Go/No Go) based on the nominal web width. These systems allow the operator to enter a nominal width value along with the product width tolerances for warning and alarm limits. Some systems have the ability to allow for both positive and negative limits as well as the ability to store product recipes for various products made in the machine for faster product changeover.



Width monitoring provides a turnkey solution for manufacturers looking to add a system with limited integration into their existing machine. These systems can be installed with limited changes to the overall operation of the existing machinery.



#### Pros:



- Simple to integrate and use
- Cost-effective solution
- Could be completely standalone or turnkey system



#### Cons:



- No data collected, hence cannot gain any meaningful insights from the measurements
- Cannot take advantage of IIoT data insights



## Roll-2-Roll® Sensor for Width Measurement and Monitoring



The Roll-2-Roll® Sensor is more than just a sensor; it is a line scan camera with an integrated light source. Combined with the Roll-2-Roll® Controller, the sensing system acts more like a machine vision solution but without the complexities of a typical vision system.



### Working Principle



The working principle of the Roll-2-Roll® Sensor is similar to any camera-based vision system; light reflected or scattered from the web is received by the camera through a proprietary linear optical system.



The optics in the Roll-2-Roll® Sensor is based on patented fiber optic technology that spatially filters the scattered/reflected light to create an image on the 1D camera. The sensors by themselves do not have any intelligence; they only have the hardware (lighting, optics, and imaging). The controller is the one that triggers the lighting and image capture sequence. Once the image is captured, it is transferred and processed by the Roll-2-Roll® Controller. The image captured by the camera is processed using digital image processing algorithms to determine the edge of the web or an edge of a contrasting feature on the web.



The 1D cameras on the Roll-2-Roll® Sensor have a hardware resolution of 0.0635 mm or 0.127 mm. The field of view of the sensor also ranges from 48 mm to 960 mm with 768 pixels to 15,180 pixels. Unlike conventional line scan cameras with circular optics, the Roll-2-Roll® Sensor has linear optics. The linear optics provide a 1:1 image capture magnification without the inversion of the image. This allows for the Roll-2-Roll® Sensor to be installed very close to the web, allowing for better lighting control and easier installation in tight installation spaces. Additionally, because of the 1:1 magnification, the resolution of the image captured is not affected by the field of view of the sensor. The linear optics also do not have any issues with aberrations and distortion, commonly seen in circular optics line scan cameras. Finally, the pixel size for 1D cameras in the Roll-2-Roll® Sensor is much larger than conventional line scan cameras, therefore requiring much less light/energy.



Overall, the Roll-2-Roll® Sensor is a specialized 1D line scan camera with some unique features that are best suited for web guiding, web width measurement, and some web inspection applications. Paired with the Roll-2-Roll® Controller, the overall system is user-friendly and as simple to use as a sensor, hence we prefer to call them sensors instead of cameras..



### Advantages



The Roll-2-Roll® Sensor system functions like a one-dimensional camera-based vision system but acts like a user/operator-friendly sensor. When compared to conventional edge sensors, the Roll-2-Roll® Sensor has the following advantages:



- Does not require calibration
- Not affected by material properties
- Can detect web edge position as well as contrasting features on the web
- Does not have issues with spatial ambiguity
- Does not require an opposing beam (fork style) transmitter/sensor configuration rather a one-sided compact solution
- Resolution is not affected by the sensor measurement range
- Compact one-sided solution with a wide field of view



On the other hand, when compared to camera-based machine vision systems, the Roll-2-Roll® Sensor has the following advantages:



- Simple installation
- Simple intuitive user interface, no programming needed by a vision "expert"
- Modular solution with integrated light source
- Compact one-sided solution
- No special, expensive gantry needed for installation
- No backlight or external lighting needed
- Unaffected by ambient light
- Can be installed close to the web, ideal for tight installation spaces
- 1:1 image magnification
- Less expensive compared to conventional camera-based solutions (total cost of ownership)



It should be noted that the Roll-2-Roll® Sensor has certain advantages compared to camera-based machine vision systems, but it is not suitable for all applications, especially those that require advanced inspection capabilities. Our sensors excel in simple inspection applications such as web width measurement, width of a coating measurement, flag detection, splice detection, tear detection, multiple strip width measurement, multiple strip gap measurement, thread/string counting, etc.



### Sensor Installation Recommendation: Edge Sensing



For web width measurement based on the edge of the web, the Roll-2-Roll® Sensor should be installed in a free span with certain background requirements. Since these are one-sided camera-like devices, no object within a distance of 150 mm should be present in the field of view of the sensor, other than the web itself. This is the safe distance measurement, but for certain applications, this constraint can be lowered. For example, if the background is a matte black object (such as a rubber-covered roller), then this distance is significantly reduced. For more information about sensor installation recommendations, please refer to the [detailed documentation](https://r2r.tech/documentation/sensor-installation-recommendations).



### Sensor Installation Recommendation: Contrast Feature Applications



![Sensor Installation Contrast Application](https://r2r.tech/sites/default/files/inline-images/Sensor%20Parallel_0.png)Apart from the background requirement, the web plane needs to be very stable for any application that requires measuring the width of the web based on a contrasting feature on the web. This requirement is no different from any camera-based inspection methods. The main reason for this requirement is to ensure that the focus of the image is not lost due to the web plane change. Meeting this requirement is easy as long as the sensor can be installed between two parallel rollers with a short span, as shown here.



For certain applications, the Roll-2-Roll® Sensor can also be installed on a backup roller. This is one of the unique advantages of the one-sided sensing compared to fork-style edge sensors. This can stabilize the web completely while providing very accurate measurement. Please consult an application engineer for more information on this type of installation or refer to the [detailed documentation](https://r2r.tech/documentation/sensor-installation-recommendations-inspection-applications) on our website.



### Web Width Measurement Based on Web Edge With One Sensor



![Web width measurement with Roll-2-Roll® Sensor](https://r2r.tech/sites/default/files/inline-images/Web-Width-Low-Basis-Weight-Nonwoven.jpg)When the sensor is wider than the width of the web (plus any web wander), then one sensor can be used for web width measurement. This is a simple installation with good accuracy of measurement.



As long as the plane of the web is stable, this measurement could provide high-resolution output. A standard camera with a 0.127 mm (0.005”) hardware resolution can be further improved with a software sub-pixel approximation algorithm to achieve a resolution of up to 0.03175 mm (0.00125”). Higher resolution camera hardware can also increase the hardware resolution to 0.0635 mm (0.0025”) and the software resolution to 0.015875 mm (0.000625”). Best of all, the resolution is not affected by the field of view of the Roll-2-Roll® Sensor.



#### Commissioning



The system can be commissioned for web width measurement by first installing the sensor as per the installation recommendations.



- Enable the appropriate sensor connected to the Roll-2-Roll® Controller and ensure that the sensor is in center mode with width measurement mode enabled.
- If needed, the parameters for the image capture can be set on the Roll-2-Roll® controller by appropriately selecting the brightness and the contrast for the image being captured. It is recommended that the image seen by the controller is bright and solid, by removing any low-contrast features seen in the image.
- For measurement applications with analog output: Choose the analog output range on the controller. Available options: 0 - 10 V, 0 - 5V, ± 10 V, ± 5 V, 0 - 10 mA, 0 - 20 mA, 0 - 24 mA, or 4 - 20 mA. If needed, change the polarity for the output.
- With good image capture conditions, the Roll-2-Roll® Controller can be taught to compensate for any focus errors or distance errors. This is necessary for calibration purposes. Subsequent calibration is not necessary if the image capture conditions or the sensor installation do not change.
- For monitoring applications with discrete digital output, set the nominal width, upper, and lower limit for alarm outputs.
- For measurement and monitoring applications with industrial ethernet, the data from the controller will be provided through the respective industrial ethernet protocol. The register map for all the information from the controller can be found on this page on our website.



#### Standard Operating Procedure



The standard operating procedure is only relevant for turnkey monitoring applications.



- Set the nominal web width, upper limit, and lower limit whenever a new product is being run so that the measurement tolerances are appropriately applied for the product.



#### Applications



Single sensor web width measurement is best suited for converting applications such as:



- shrink sleeve converting
- diaper manufacturing
- narrow blown film manufacturing (shrink tubes and medical IV bags)
- hook and loop fasteners converting
- self-lock zipper extrusion
- zipper converting
- window shade converting
- metal strip converting
- plastic sheet extrusion
- seat belt manufacturing



Apart from measuring a single web width, multiple web width measurements are also possible with a single sensor. Moreover, since more than one sensor can be connected to the Roll-2-Roll® Controller, a single or multiple web width measurement from each sensor can be measured. These are specialized scenarios available only with special firmware versions. Consult the factory for more details.



These functionalities are only available with Roll-2-Roll® Controller having the digital industrial ethernet option. This is because the Roll-2-Roll® Controller has one analog and limited discrete digital outputs which are best suited for a single web width measurement application. Whereas with the digital industrial ethernet output option, multiple data values can be provided over that channel. Additionally, with the digital input option available with industrial ethernet, nearly unlimited amounts of data can be transmitted from the Roll-2-Roll® Controller to an industrial PC or PLC.



Some common applications for multiple web width measurements are:



- metal strip converting
- slitting width measurement
- flat ribbon cable converting
- paper slitting
- hook and loop fasteners slitting
- tape slitting
- Lithium-Ion battery (anode and cathode) slitting



### Web Width Measurement Using Two Sensors Based on Web Edge



Single sensor web width measurement may not always be cost-effective, especially for wider webs exceeding 900 mm. For instance, the current maximum range for Roll-2-Roll® Sensor is 960 mm. When the maximum web width is 900 mm and the minimum web width is 800 mm, it's unnecessary to use the 960 mm Roll-2-Roll® Sensor. In this case, a two-sensor option is more appropriate as long as their combined width covers the difference between the maximum and minimum web widths of products run in the machine.



#### Commissioning



The system can be commissioned for web width measurement by first installing the sensor as per the installation recommendations.



- Install the two sensors as per the installation recommendations.
- Enable both sensors connected to the Roll-2-Roll® Controller, ensuring that the sensor looking at the left edge is in left edge mode and the one looking at the right edge being set to right edge mode for a single wide web.
- If needed, set the parameters for image capture on the Roll-2-Roll® controller by selecting the appropriate brightness and contrast for each sensor.
- For measurement applications with analog output: Choose the analog output range on the controller. Available options: 0 - 10 V, 0 - 5V, ± 10 V, ± 5 V, 0 - 10 mA, 0 - 20 mA, 0 - 24 mA, or 4 - 20 mA. If needed, change the polarity for the output.
- Teach the Roll-2-Roll® Controller to compensate for any focus errors, distance errors, and the offset distance (distance between the two sensors) for calibration purposes.
- For monitoring applications with discrete digital output, set the nominal width, upper, and lower limit for alarm outputs.
- For measurement and monitoring applications with industrial ethernet, the data from the controller will be provided through the total width output register, which can be found on this page on our website.



#### Standard Operating Procedure



The standard operating procedure is only relevant for turnkey monitoring applications.



- Set the nominal web width, upper limit, and lower limit whenever a new product is being run.
- If sensors are repositioned, teach the controller to learn the offset distance between the two sensors.



#### Applications



Dual sensor web width measurement is best suited for wide web applications such as:



- Blown film layflat web width measurement
- Textile manufacturing
- Tire manufacturing
- Metal strip manufacturing
- Corrugated board manufacturing
- Paper converting
- Wide web converting



### Web Width Measurement Based on Contrasting Position with One Sensor



Roll-2-Roll® Sensors with an appropriate light source can detect contrasting features on the web and measure the width of the contrasting feature. For example, the distance between the edge of a Lithium-Ion battery anode or cathode from the edge of the coating (tab or trim width) can be measured using the contrast width measurement. The entire contrasting feature needs to be within the sensor's field of view.



The system can be commissioned for web width measurement by first installing the sensor as per the installation recommendations.



- Install the sensor as per the installation recommendations.
- Enable the appropriate sensor connected to the Roll-2-Roll® Controller, set the sensing mode to contrast mode, and ensure width measurement mode is enabled.
- If needed, set the parameters for image capture on the Roll-2-Roll® controller by selecting the appropriate brightness and contrast.
- Teach the Roll-2-Roll® Controller to track the position and width of the feature using one of the three contrast modes:  Left edge of a selected contrast
- Right edge of a selected contrast
- Line mode with a certain background contrast

  For measurement applications with analog output: Choose the analog output range on the controller. Available options: 0 - 10 V, 0 - 5V, ± 10 V, ± 5 V, 0 - 10 mA, 0 - 20 mA, 0 - 24 mA, or 4 - 20 mA. If needed, change the polarity for the output. Teach the Roll-2-Roll® Controller to compensate for any focus errors or distance errors for calibration purposes. Subsequent calibration is not necessary if the image capture conditions or the sensor installation does not change. For monitoring applications with discrete digital output, set the nominal width, upper, and lower limit for alarm outputs. For measurement and monitoring applications with industrial ethernet, the data from the controller will be provided through the respective industrial ethernet protocol, which can be found on our [website](https://r2r.tech/documentation/scu5-xcxd-register-map-v36g).

#### Standard Operating Procedure



The standard operating procedure is necessary for any time a new contrasting feature is being selected.



- Select and teach the Roll-2-Roll® Controller to track the appropriate feature width every time a new feature needs to be tracked.
- Set the nominal web width, upper limit, and lower limit whenever a new product is being run.



#### Applications



Some common applications for contrast width measurement include:



- Lithium-Ion battery anode/cathode trim and tab width measurement
- Width measurement from the edge of the web to the edge of the printing in packaging
- Tire and rubber width measurement on a backup roller with a bright background
- Selvage width measurement in textile converting
- Coating width measurement in paper manufacturing and adhesive tape manufacturing
- UV fluorescent glue width measurement in diaper and hygiene products converting
- Width from the edge of the release liner to the die-cut edge of the label in label slitting



Multiple contrasting features can be tracked with a single sensor or with both sensors connected to the Roll-2-Roll® Controller using specialized firmware for custom applications. Consult the factory for more information.



### Web Width Measurement Based on Contrasting Position with Two Sensors



Two sensors can be used to measure the width of a single web based on two contrasting features on the web. For example, the web width in an embossing process can be measured by tracking printed registration marks on either side of the web. This may be necessary especially with multilayer laminated webs such as in holographic embossing process.



The system can be commissioned for web width measurement by first installing the sensors as per the installation recommendations.



- Install the two sensors as per the installation recommendations.
- Enable both sensors connected to the Roll-2-Roll® Controller, set the sensing mode to contrast mode, and ensure width measurement mode is enabled.
- If needed, set the parameters for image capture on the Roll-2-Roll® controller by selecting the appropriate brightness and contrast.
- Teach each sensor image in the Roll-2-Roll® Controller to track the position and width of the feature using one of the three contrast modes:  Left edge of a selected contrast
- Right edge of a selected contrast
- Line mode with a certain background contrast

  For measurement applications with analog output: Choose the analog output range on the controller. Available options: 0 - 10 V, 0 - 5V, ± 10 V, ± 5 V, 0 - 10 mA, 0 - 20 mA, 0 - 24 mA, or 4 - 20 mA. If needed, change the polarity for the output. Teach the Roll-2-Roll® Controller to compensate for any focus errors, distance errors, and the sensor offset distance between the two sensors for calibration purposes. For monitoring applications with discrete digital output, set the nominal width, upper, and lower limit for alarm outputs. For measurement and monitoring applications with industrial ethernet, the data from the controller will be provided through the respective industrial ethernet protocol, which can be found on our [website](https://r2r.tech/documentation/scu5-xcxd-register-map-v36g).

#### Standard Operating Procedure



The standard operating procedure is necessary for any time a new contrasting feature is being selected.



- Select and teach the Roll-2-Roll® Controller to track the appropriate feature corresponding to the appropriate sensor every time a new feature needs to be tracked.
- Set the nominal web width, upper limit, and lower limit whenever a new product is being run.
- If sensors are repositioned, teach the controller to learn the offset distance between the two sensors.



#### Applications



Some common applications for two sensor contrast width measurement include:



- Necking width measurement in embossing applications
- Tire and rubber width measurement
- Carpet width measurement based on tufting edge
- Extrusion lamination coating width measurement
- Plastic bale bag width measurement



In summary, the Roll-2-Roll® Sensor system offers various web width measurement solutions based on the specific application requirements. Single sensor and dual sensor configurations, as well as edge-based and contrast-based measurement methods, provide users with the flexibility to adapt the system to a wide range of industries and applications. By following the appropriate commissioning and standard operating procedures, users can optimize the performance of the Roll-2-Roll® Sensor system for accurate and reliable web width measurements.



### Output Options from Roll-2-Roll® Controller



Various output options are available for web width measurement applications with the Roll-2-Roll® Controller. This section provides more information on the output with respect to the different options available.



#### Analog



The analog option outputs either a voltage or current from the Roll-2-Roll® Controller. Various voltage or current ranges are available in the controller. However, regardless of the voltage range, the digital-to-analog converter in the controller has a 12-bit resolution, meaning 4096 discrete output levels irrespective of the output range. Therefore, the minimum delta in voltage or current level change output from the controller is ds = Fs/4096, where Fs is the full-scale range in voltage or current.



The analog value output from the Roll-2-Roll® Controller depends on the number of sensors used and the measurement range for the sensor(s) used; however, there is only one web width measurement output.



#### Single Sensor Analog Output



The analog output can provide both an absolute web width and the error from the nominal value based on the selection in the Roll-2-Roll® Controller.



##### Absolute Web Width



For a single sensor width measurement application with a sensor measurement range of 97.028 mm and a voltage output range of 10 V, a product measuring 63.5 mm would have an analog voltage value of:

 Ao = 10*(63.5/97.028) =6.5445 V

The sensor measurement range of any Roll-2-Roll® Sensor can be computed by knowing the number of pixels in the sensor and the resolution of the sensor. For example, ODC 96-IR QD HR has 764 pixels with a hardware resolution of 0.127 mm, resulting in a measurement range of 97.028 mm. Technically, the analog output is calculated based on the pixel width measured by the controller with integer quantization as shown below:

 Ao = round(4096 * Wp/Np)*ds

where Wp is the width in pixels, Np the total number of pixels in the sensor, ds = Fs/4096.



##### Error in Web Width



When a nominal width is set in the Roll-2-Roll® Controller, the error in measurement is provided as the output. With the same example above, if the nominal width is set as 65.024 mm, the analog output value is calculated based on:

 Ao = HS + round(4096 * Ep/Np )*ds

where the error Ep = NWP - Wp with NWP being the nominal web width discretized into pixels and WP being the measured web width in pixels. HS is the half-scale value of the analog range. When the error is zero, the output will be exactly half scale. This is where the ±10V or ± 5V analog output ranges are useful for feedback control based on web width measurement.



#### Dual Sensor Analog Output



Dual sensor analog output is slightly different from the single sensor analog output option.



##### Absolute Web Width



The main difference lies in the absolute web width output. Regardless of the distance between the two sensors, the analog output with this option is always proportional to the portion of the web seen by both sensors. The primary reason for this is to improve the measurement resolution when the distance between the two sensors is wide compared to the measurement range of the sensors.



The analog output is calculated based on the portion of the web seen by both sensors in the number of pixels with integer quantization as shown below:

 Ao = round(4096 * (Wp1 + Wp2)/(Np1+Np2))*ds

where Wp1 and Wp2 are the portions of the web seen by Sensor 1 and Sensor 2 in pixels, Np1 and Np2 are the total number of pixels in Sensor 1 and Sensor 2, and ds = Fs/4096.



It is recommended that for two-sensor applications, both sensors have the same web measurement range and resolution.



##### Error in Web Width



When a nominal width is set in the Roll-2-Roll® Controller, the error in measurement is provided as the output. The difference in this case is that the denominator includes the sum of pixels in the two sensors, as shown below:

 Ao = HS + round(4096 * Ep/(Np1+Np2) )*ds

where the error Ep = NWP - Wp, with NWP being the nominal web width discretized into pixels and WP being the measured web width in pixels (including the offset between the two sensors). HS is the half-scale value of the analog range.



#### Discrete Digital: Pass/Fail



Two or four discrete digital outputs (NPN mode) are also available as output options for the Roll-2-Roll® Controller. These 24V-compatible discrete outputs can provide a simple pass/fail output for turnkey web width measurement applications.



The outputs are based on the nominal web width, upper limit, and lower limit values. If the error in the web width is greater than the upper limit value, that output will be triggered. Likewise, if the error is below the lower limit value, that output will be triggered.



These outputs can be connected to a stack light or an audible alarm signal to alert the operator when the width is outside the normal operating range. It should be noted that this output is for only one web width, irrespective of whether one or two sensors are used for measurement.



#### Digital: Industrial Ethernet (PLC or Web Dashboard)



The most accurate and versatile of the output options is the digital industrial Ethernet option. Roll-2-Roll® Controller also supports a variety of open industrial Ethernet protocols, such as EtherNet/IP, PROFINET, EtherCAT, Modbus/TCP, and CC-Link IE, for easy connectivity and data exchange. The data is available via I/O data exchange with real-time data update rates. The register map for the controller can be found on this page on our website, and the support files for various industrial Ethernet protocols are available on our website as well. For more information, please consult the factory or an application engineer.



As part of these industrial Ethernet options, Roll-2-Roll® Controller also has a built-in web server that enables rapid deployment of the system using a web browser-based dashboard. This dashboard provides real-time data transfer from the controller to the computer. Apart from plotting the data in real-time, the dashboard also allows for easy data collection and data logging.



## Why use Roll-2-Roll® Sensor and Controller for Web Width Measurement?



The Roll-2-Roll® Sensor is more than a conventional sensor and behaves similarly to camera-based technology. The Roll-2-Roll® Controller helps by reducing the complexity of the system and allowing for a user-friendly operator interface that anyone can use. The advantages can be specifically categorized into the following:



### Advantages of the One-Sided Sensor Solution:



- Allows for installation very close to a roller or on a roller, with the following benefits:  Stabilizes the web by setting the web plane for superior measurement accuracy
- Removes air entrained in the web, especially with the shrink sleeve application
- Sets a constant background for installation in tight spaces

  Allows for the installation to take advantage of gravity to reduce dust accumulation Compact footprint ideal for tight installation spaces Easy threading of the web and avoids sensor damage from operator threading errors

### Advantages of the Modular Design:



With the integrated light source, optics, and 1D camera within a compact profile, the modular design provides the following advantages:



- Close installation to the web with increased measurement resolution and accuracy
- Eliminates the need for external lighting
- Eliminates the need to build a gantry for light source and camera installation
- Eliminates the need for long working distance required for conventional camera solutions



### Advantages of the Linear Optics:



- 1:1 magnification with higher resolution
- Eliminates lens distortion or aberrations common with circular lens optics
- Resolution of the measurement is not affected by the field of view of the camera
- Working distance not affected by the field of view of the camera
- Camera vibrations does not get magnified in the image captured



### Advantages of the Roll-2-Roll® Controller:



- Simple, intuitive, user-friendly operator interface
- No programming needed for setup or operation
- Setup and calibration can be done by operators without the need for “vision experts”
- Integrated control of the lighting (illumination) eliminates lighting errors



In conclusion, the Roll-2-Roll® Sensor and Controller system represents a groundbreaking solution for web width measurement applications, delivering unparalleled accuracy, versatility, and ease of use. Its innovative one-sided sensor design, compact modular structure, and advanced linear optics eliminate common challenges faced in industrial settings, while the user-friendly Roll-2-Roll® Controller ensures effortless setup and operation without the need for specialized expertise.



By choosing the Roll-2-Roll® Sensor and Controller system, you can optimize your web width measurement processes, boost productivity, and enhance overall performance. Don't miss out on the opportunity to transform your operation and stay ahead of the competition. Take action today and upgrade to the Roll-2-Roll® Sensor and Controller system – the future of web width measurement technology.

---

#  All Up In Your Science Business

URL: https://r2r.tech/news/all-your-science-business.md

The Oklahoma Proof of Concept Center (POCC), an i2E program, is designed to educate scientists, students, and entrepreneurs about the business of science with the goal of creating new and better entrepreneurs and businesses in the state of Oklahoma.

---

#  Stillwater Company Receives Investment

URL: https://r2r.tech/news/stillwater-company-receives-investment.md

The i2E Inc.-managed Oklahoma Seed Capital Fund recently closed a $250,000 investment, leading a $520,000 financing round, in a Stillwater-based company that is developing advanced technology that enhances manufacturing from rolled materials such as diapers.

---

# 2014 LaunchOklahoma Program Participants & Attendance

URL: https://r2r.tech/news/2014-launchoklahoma-program-participants-attendance.md

With our 2014 accelerator program at an end, we want to give credit and thanks to everyone who contributed to making our 2014 LaunchOklahoma Open Accelerator Program a success. Here’s a look at our events and the companies who participated, presented, and attended.

---

# 2014 Open Accelerator Wrap-up – Participants Share Their Experience

URL: https://r2r.tech/news/2014-open-accelerator-wrap-participants-share-their-experience.md

With our 2014 program at it’s end, we would like to thank everyone who attended our open accelerator workshops, seminars, and networking events during our 12-week program. In an effort to reach out to the local entrepreneurial community, we opened up our 2014 accelerator program workshops to local entrepreneurs. These workshops featured LaunchOklahoma mentors, sponsors, and leading, local professionals presenting on a range of business topics for startup companies.

---

# A Start-up’s Biggest Obstacle: Funding

URL: https://r2r.tech/news/start-ups-biggest-obstacle-funding.md

I write a lot about access to capital. The obvious reason is that it takes money to start a business. But there’s a second really important aspect to the challenge of raising capital — fundraising really weighs down entrepreneurs.

---

# Chip Shortage Spirals Beyond Cars to Phones and Consoles

URL: https://r2r.tech/news/chip-shortage-spirals-beyond-cars-phones-and-consoles-0.md

The article by Debby Wu, Vlad Savoy and Takashi Mochizuki for Bloomberg looks at the reason automakers are shutting down assembly operations due to lack of chips, and how this could extent to other industrial sectors. 



Should converting OEMs and equipment manufacturers be concerned

---

# Coronavirus - Supplier and converter statements

URL: https://r2r.tech/news/coronavirus-supplier-and-converter-statements.md

Roll-2-Roll Technologies LLC was mentioned as one of the companies in the converting industry issuing statements outlining their business continuity plans through the Coronavirus pandemic.



Suppliers and converters are working hard to ensure that the supply of their products and services to customers remain constant and secure while they manage through the global Covid-19 coronavirus situation. 

---

# Electric vehicle battery manufacturer Microvast to establish a manufacturing facility in Clarksville, TN

URL: https://r2r.tech/news/electric-vehicle-battery-manufacturer-microvast-establish-manufacturing-facility-clarksville.md

Microvast Power Solutions, a US owned company that makes electric vehicle batteries, is establishing a manufacturing facility in Clarksville. The venture is expected to bring over 280 jobs to the area. 

---

# EtherCAT Technology Group welcomes Roll-2-Roll Technologies LLC as member number 6,000

URL: https://r2r.tech/news/ethercat-technology-group-welcomes-roll-2-roll-technologies-llc-member-number-6000.md

11/2020 | **The latest membership milestone in the growth of the EtherCAT Technology Group (ETG)** shows that EtherCAT technology is successfully defying the current global crisis: The **American sensor manufacturer Roll-2-Roll Technologies LLC **recently became member number 6,000 of the world's largest fieldbus user organization.

---

# Fifteen Applied Research Projects Receive $3.5 Million In Awards From OCAST

URL: https://r2r.tech/news/fifteen-applied-research-projects-receive-35-million-awards-ocast.md

Fifteen Applied Research applications chosen from a field of 39 were awarded $3,546,670 August 19 by the governing board of the Oklahoma Center for the Advancement of Science and Technology (OCAST).

---

# Governor’s Cup Winners Revealed

URL: https://r2r.tech/news/governors-cup-winners-revealed.md

Student teams from Oklahoma State University-Oklahoma City, Rogers State University and Northeastern Oklahoma A&M College finished one-two-three in the first Small Business Division competition at the annual Donald W. Reynolds Governor’s Cup.

---

# High Growth Graduate Finalists

URL: https://r2r.tech/news/high-growth-graduate-finalists.md

The six High Growth Graduate Division teams advancing to the Oral Presentation finalist round April 13 at the Presbyterian Health Foundation Conference Center in Oklahoma City. Note: Teams will receive an email with judges’ comments and additional information on the oral competition by Monday, March 25.

---

# High Growth Graduate Finalists

URL: https://r2r.tech/news/high-growth-graduate-finalists-0.md

The six High Growth Graduate Division teams advancing to the Oral Presentation finalist round April 13 at the Presbyterian Health Foundation Conference Center in Oklahoma City. Note: Teams will receive an email with judges’ comments and additional information on the oral competition by Monday, March 25.

---

# I&E Winter 2014 Magazine Article About Roll-2-Roll Technologies

URL: https://r2r.tech/news/ie-winter-2014-magazine-article-about-roll-2-roll-technologies.md

Aravind Seshadri is talking diapers. Hundreds of millions of them. He’s focused on the way they are manufactured and the speed at which the material that becomes diapers flies through the machinery from one roll to another.

---

# Innovator Profile: Roll-2-Roll Technologies LLC

URL: https://r2r.tech/news/innovator-profile-roll-2-roll-technologies-llc.md

Aravind Seshadri takes the old adage that time is money very seriously. So seriously that he started pursuing an idea to develop technology to solve existing problems while still attending Oklahoma State University. The fruit of his labor is his company, Roll-2-Roll Technologies LLC.

---

# Leading Progress: 21 Make The Cut As Journal Record Innovator Of The Year Finalists

URL: https://r2r.tech/news/leading-progress-21-make-cut-journal-record-innovator-year-finalists.md

From advancements designed to improve drug delivery technology and increase manufacturing productivity to products aimed to reduce the nation's feral hog population, this year’s group of honorees for The Journal Record’s Innovator of the Year program shows much promise.

---

# Oklahoma Entrepreneurship: Roll-2-roll Spins Plan From Idea To Business

URL: https://r2r.tech/news/oklahoma-entrepreneurship-roll-2-roll-spins-plan-idea-business.md

I have a story. It’s the story of a handful of college students with remarkable focus and tenacity, a spin-out technology from OSU, and $520,000 in Oklahoma-raised seed stage capital.

---

# Oklahoma Innovations For Feb. 1-2 (Audio)

URL: https://r2r.tech/news/oklahoma-innovations-feb-1-2-audio.md

Oklahoma Innovations Radio Show Air Date: February 1-2, 2014 Guests: Aravind Seshadri and Pedro Velasco, Roll-2-Roll Technologies (R2R)

---

# Oklahoma Innovations For Feb. 1-2 (Transcript)

URL: https://r2r.tech/news/oklahoma-innovations-feb-1-2-transcript.md

Oklahoma Innovations Radio Show Air Date: February 1-2, 2014 Guests: Aravind Seshadri and Pedro Velasco, Roll-2-Roll Technologies (R2R)

---

# Oklahoma Resources Put Aravind Seshadri And His New Company On A Roll

URL: https://r2r.tech/news/oklahoma-resources-put-aravind-seshadri-and-his-new-company-roll.md

Aravind Seshadri, founder and CEO of Roll-2-Roll Technologies, came to Oklahoma from India to earn his master's degree in mechanical engineering at Oklahoma State University. He liked Oklahoma and OSU so well that he applied to earn his Ph.D.

---

# Oklahoma Startup Supporter Says 2014 Was A Significant Year For Oklahoma's Innovation Economy

URL: https://r2r.tech/news/oklahoma-startup-supporter-says-2014-was-significant-year-oklahomas-innovation-economy.md

This week, when we are between the old and the new year, I can’t help reflecting on the accomplishments of the last twelve months and anticipating all of the possibilities of the new year ahead.

---

# Oklahoma State University Student-led Business Wins $30,000 At Donald W. Reynolds Cup

URL: https://r2r.tech/news/oklahoma-state-university-student-led-business-wins-30000-donald-w-reynolds-cup.md

R2R Technologies, an Oklahoma State University student-led business, was one of the major winners at the Tri-State Donald. W. Reynolds Cup business plan competition in Las Vegas on Tuesday night.

---

# Oklahoma State University Student-led Business Wins $30,000 At Donald W. Reynolds Cup

URL: https://r2r.tech/news/oklahoma-state-university-student-led-business-wins-30000-donald-w-reynolds-cup-0.md

R2R Technologies, an Oklahoma State University student-led business, was one of the major winners at the Tri-State Donald. W. Reynolds Cup business plan competition in Las Vegas on Tuesday night.

---

# Oklahoma Teams Win In Las Vegas

URL: https://r2r.tech/news/oklahoma-teams-win-las-vegas.md

Teams from the University of Oklahoma and Oklahoma State University were named first place winners in both Graduate and Undergraduate divisions of the Donald W. Reynolds Tri-State collegiate business plan competition here Tuesday night.

---

# OSU Student-led Business Is Growing

URL: https://r2r.tech/news/osu-student-led-business-growing.md

Roll-2-Roll Technologies, an Oklahoma State University student-led business founded in 2013, is growing thanks to raising a considerable amount of capital this summer.

---

# OU, OSU Teams Win Business Plan Competition

URL: https://r2r.tech/news/ou-osu-teams-win-business-plan-competition.md

Teams from the University of Oklahoma and Oklahoma State University were first-place division winners of the Donald W. Reynolds Tri-State collegiate business plan competition in Las Vegas.

---

# OU, OSU Teams Win Competition

URL: https://r2r.tech/news/ou-osu-teams-win-competition.md

Teams from the University of Oklahoma and Oklahoma State University were named first-place winners in both Graduate and Undergraduate divisions of the Donald W. Reynolds Tri-State collegiate business plan competition in Las Vegas Tuesday night. FieldFocus from OU was named Undergraduate Division winner, while Roll-to-Roll Technologies from OSU was named Graduate Division winner. Each team won $30,000. The Tri-State is a business plan competition featuring the top two winning teams in Graduate and Undergraduate Divisions from Donald W. Reynolds Governor's Cup competitions in Oklahoma, Arkansas and Nevada.

---

# Press Release - Roll-2-Roll Technologies LLC announces launch of new wide range sensor for the converting industry

URL: https://r2r.tech/news/press-release-roll-2-roll-technologies-llc-announces-launch-new-wide-range-sensor-converting.md

Stillwater, OK, August 29th, 2020– Roll-2-Roll Technologies LLC launched at Converters Expo it's latest development, the WPS 900 sensor . This sensor provides a sensing range of 35.4" (900 mm), making it the widest sensing range in the industry.



The WPS 900 has the same versatility as the rest of the Roll-2-Roll® Sensor product line, allowing converters to use it in multiple applications on their manufacturing line.

 The main features of the WPS 900 are:



- Widest proportional band sensor in the industry
- High resolution in a wide sensor, standard mode resolution of 0.005" (0.127 mm) with a higher resolution of .0025" (0.0635 mm) available
- Open standard for industrial ethernet protocol through its controller unit.
- Tracking of up to 256 edges.
- One sensor for multiple applications: width measurement, edge, center and line guiding, flag detection, mark detection contrast position measurement with appropriate light source
- One side sensor - compact profile for installation in spaces other sensors cannot fit.



Benefits of the WPS 900 include:



- No repositioning of sensors. Its wide sensing range provides cost reduction with improved accuracy in comparison with systems that reposition sensors.
- No need for sensor calibration, so you can process nonwovens, meshes, film and many other materials with no down time.



Aravind Seshadri, President of Roll-2-Roll Technologies indicated that “customers have always inquired about a wider sensing range to get greater coverage of their web. The result of our R&D work is a wide sensing range sensor with great resolution and compact design, for a simple to use sensor.”



Roll-2-Roll Technologies hosted live demo sessions of their entire line of products during Converters Expo. These live online demo sessions are available by booking a time slot at the Roll-2-Roll Technologies website: https://r2r.tech/schedule-live-demo .



Roll-2-Roll Technologies LLC invites all converters and related industries to visit its website at https://r2.tech periodically to keep updated on new products and development, and its library of instructional papers and videos. 



Roll-2-Roll Technologies LLC provides the most advanced and simple to use web positioning sensor technology for the converting industry and general automation. The nimble technical company, we are the disruptors of the web handling industry for the benefit of our customers.




 # # #




 If you would like more information about this topic, please contact Pedro Velasco at 405-726-0731 or email at marketing@r2r.tech. Visit the  company website at r2r.tech for additional resources, whitepapers and instructional videos.

---

# R2R Technologies Wins National Contest

URL: https://r2r.tech/news/r2r-technologies-wins-national-contest.md

R2R Technologies, an Oklahoma State University student-led business, was one of the major winners at the Tri-State Donald W. Reynolds Cup business plan competition in Las Vegas last May.

---

# Research Investment Returns Dividends To OSU

URL: https://r2r.tech/news/research-investment-returns-dividends-osu.md

An Oklahoma State University program that invests and assists with technology commercialization has returned to the university $4.50 for every $1 invested, according to the Technology Development Center, which launched the program a decade ago. The gap fund has given a $2.37 million financial boost to more than 100 OSU technology developments with more than two dozen becoming businesses.

---

# Roll-2-Roll Introduces ODC 960 Sensor

URL: https://r2r.tech/news/roll-2-roll-introduces-odc-960-sensor.md

Roll-2-Roll Technologies introduces its latest product, the ODC 960 sensor. Boasting a sensing range of 37.8 inches and a resolution of 0.005" or 0.127 mm, the ODC 960 sets a new industry standard for wide-range sensors, providing unparalleled precision for converters seeking the utmost accuracy in their converting applications.

---

# Roll-2-Roll Scores $520k

URL: https://r2r.tech/news/roll-2-roll-scores-520k.md

Roll-2-Roll Technologies has received $520,000 in funding. The investors included Oklahoma Seed Capital Fund and SeedStep Angels, both of which are managed by i2E. Cowboy Technologies and the co-founders of Roll-2-Roll also participated in the round. Based in Stillwater, Oklahoma, Roll-2-Roll is developing a lateral guide for manufacturers that produce consumer products with raw materials that come in the form of rolls.

---

# Roll-2-Roll Technologies Introduces a New Wide Sensor for Web Handling

URL: https://r2r.tech/news/roll-2-roll-technologies-introduces-new-wide-sensor-web-handling.md

Roll-2-Roll Technologies LLC is introducing ARIS WPS 440 IR, its newest product in web positioning sensors for the converting and general automation industry. The ARIS WPS 440 IR includes all the features of the rest of the ARIS WPS line of sensors, providing a sensing window of 440 mm and integrated sensor control unit.

---

# Roll-2-Roll Technologies Introduces New Line of Retrofit Kits for Web Guiding Systems

URL: https://r2r.tech/news/roll-2-roll-technologies-introduces-new-line-retrofit-kits-web-guiding-systems.md

Many operations in need of upgrading their current converting line have to deal with replacement of outdated components, such as web guides. Many still run controls and sensors that have been obsolete for years. The mechanical components might still be sound, or they could be rebuilt at a low cost. However, does it make sense to have a web guide with outdated controls and sensors? 

---

# Roll-2-Roll Technologies Launches Business

URL: https://r2r.tech/news/roll-2-roll-technologies-launches-business.md

Nine out of 10 entrepreneurship companies fail, according to the Kauffman Foundation. Roll-2-Roll Technologies plans to be the other one out of 10.

---

# Roll-2-Roll Technologies launches new web detection linear cameras technology

URL: https://r2r.tech/news/roll-2-roll-technologies-launches-new-web-detection-linear-cameras-technology.md

**Features and Benefits of ODC Linear Cameras: **



- New and improved CMOS line scan camera with high dynamic range
- Elimination of motion blur with a global shutter
- Up to 4x the scan rate compared to WPS
- Improved sensitivity to pick hard to sense materials and low contrast difference
- Same enclosure profile as the WPS line of sensor products. Low profile allows for placement in restricted spaces in converting lines where other sensors cannot be used.
- When combined with the soon to be released SCU6 controller, ODC  can provide 8x the dynamic range for superior edge detection and contrast detection
- Drop-in functional replacement to existing WPS products with same cabling



![Roll-2-Roll Technologies launches new web detection camera technology](https://dev.rodpub.com/images/242/567_main.jpg)



**Applications:**



- Web guiding: Edge, line, center, pattern and contrast guiding
- Web width measurement
- Flag detection
- Registration mark detection
- Product length measurement
- Tear detection
- Simple automated defect detection



- ODC Linear Cameras are available with measurement ranges from 48 mm up to 768 mm. Light sources include: Infrared for mostly edge detection and high contrast applications, White Light (broadband) for visible contrast detection, and UV for fluorescent contrast applications. Additional LED light sources are available on request. Hardware camera resolution of 0.0635 mm (0.0025”) or 0.127 mm (0.005”). Higher firmware resolution of up to 0.015875 mm (0.000625”) available upon request.  ODC Linear Cameras will work with existing SCU5 controllers with a firmware update. Two ODC 768 can be used with a single SCU5 controller to provide a total coverage of 1536 mm (60.5”). There are additional options and increased capabilities with the soon to be released SCU6 controller.

---

# Roll-2-Roll Technologies Launches Redesigned Website With Ungated Product Data and Industry-First Cost of Inaction Calculator

URL: https://r2r.tech/news/roll-2-roll-technologies-launches-redesigned-website-ungated-product-data-and-industry-first.md

**STILLWATER, Okla., March 9, 2026 —** Roll-2-Roll Technologies, a manufacturer of patented fiber-optic web handling sensors, today launched a redesigned website at [r2r.tech](https://r2r.tech) that gives engineers and plant managers unrestricted access to the technical information they need to evaluate, specify, and justify web handling equipment.

The new platform addresses a persistent frustration in manufacturing procurement: critical product data — sensor specifications, 3D CAD models, configuration details, and competitive cost analysis — has traditionally required phone calls, email exchanges, and sales meetings to obtain. Roll-2-Roll Technologies has removed those barriers entirely. Every product specification, interactive 3D model, and branded PDF spec sheet on the site is available immediately and without registration.

The platform also introduces an interactive Cost of Inaction Calculator, an industry-first tool that enables manufacturers to quantify the annual operating costs associated with legacy web handling equipment. The calculator covers four assessment categories — sensor repositioning, manual width measurement, pneumatic and hydraulic guide maintenance, and legacy equipment downtime — with every line item supported by cited research from BCG, Siemens, and the U.S. Department of Energy. Results are generated instantly and can be downloaded and shared internally without creating an account.

The redesigned website reflects a broader company philosophy. Since its founding, Roll-2-Roll Technologies has operated on the principle that precision web handling technology should be accessible to every operator — not just specialists. The company's engineering team, which includes PhDs in web dynamics and controls engineers with decades of industry experience, develops products to a simple standard: if it requires a manual, the engineering is not finished. That same commitment to eliminating complexity now extends to how manufacturers access information. The website is designed so that an engineer on a plant floor can find a specification, inspect a 3D model, download a PDF, and assess costs in the same session — without filing a request or waiting for a response.

"Engineers and plant managers have told us the same thing for years: they know their legacy equipment carries hidden costs, but they have never had a straightforward way to quantify them," said Aravind Seshadri of Roll-2-Roll Technologies. "We built a tool that does exactly that and made it available to everyone. No login, no sales call, no strings attached. When manufacturers can see the numbers for themselves, they make better decisions."

The site now includes complete specifications for all sensor families, controllers, actuators, and web guide systems; more than 138 video pages with auto-generated transcripts and structured data; industry-specific pages spanning battery manufacturing, converting, film extrusion, flexible electronics, label and narrow web, metals, nonwovens, paper, pharma, textiles, and tire and rubber; and solution pages organized by application. Testimonials from manufacturers provide independent validation of the technology's performance across diverse production environments.

The platform already includes an online SKU configurator for sensor and controller product families, allowing engineers to select a product variant, retrieve the exact part number and specification details, and download the corresponding 3D STEP model — all without contacting sales. Configurators for web guides and actuators are in development, and Roll-2-Roll Technologies has committed to an ongoing expansion of the platform with additional application-specific content and an expanded video library of installation and troubleshooting guides.

"Every product we build and every page we publish starts with the same question: does this make the customer's job simpler?" Seshadri said. "We treat our customers as partners. When we improve their process and their bottom line, the rest takes care of itself."

### About Roll-2-Roll Technologies

Roll-2-Roll Technologies manufactures patented fiber-optic sensors for web guiding, edge detection, width measurement, and process monitoring. Originally developed at Oklahoma State University, the company's technology eliminates the daily recalibration, complex setup, and material-specific adjustments required by legacy web handling sensors. With more than 1,000 installations across 25 countries and 16 Fortune 500 customers, Roll-2-Roll sensors are deployed in industries ranging from battery manufacturing to pharmaceutical production. The company is headquartered in Stillwater, Oklahoma.

For more information, visit [r2r.tech](https://r2r.tech) or contact the engineering team at [experts@r2r.tech](mailto:experts@r2r.tech).

---

# Roll-2-Roll Technologies LLC Announces Launch of New Wide Range Sensor for Web Guiding, Width Measurement and Monitoring

URL: https://r2r.tech/news/roll-2-roll-technologies-llc-announces-launch-new-wide-range-sensor-web-guiding-width.md

Roll-2-Roll Technologies LLC is launching its latest development, the ​WPS 900 sensor​. This sensor provides a sensing range of 35.4 centimeters, making it the widest sensing range in the industry.



The WPS 900 has the same versatility as the rest of the Roll-2-Roll® Sensor product line and could allow converters to use it in multiple [applications](https://www.pffc-online.com/equipment-machines-converting) on their manufacturing line.



![WPS 900 Widest Sensing Range in the Industry for Converting Op](https://r2r.tech/sites/default/files/inline-images/WPS_900-xx_QD_2020-Jul-14_07-13-59PM-000_CustomizedView11400752869%20%281%29.png)

---

# Roll-2-Roll Technologies LLC announces new camera technology for web detection  

URL: https://r2r.tech/news/roll-2-roll-technologies-llc-announces-new-camera-technology-web-detection.md

![Roll-2-Roll Technologies Logo](https://lh5.googleusercontent.com/s8THgIJDPluQ3mzAodQ2Eh3vK2JywczwcrWEwXoUnrhVCg2P6zO9puMTooIKyuNM5IQnvqZHzZk4wXnVL1_-Du4oJrHnaTKQv4rZkmzpv3u2D34ljv-2MnrRHrulz4ww9Nxbnl5y=s0)

### Press Release

    Contact: Pedro Velasco

Telephone: 405-726-0731

          Cell: 405-614-4585

       Email: marketing@r2r.tech

   Website: [r2r.tech](https://r2r.tech)

## FOR IMMEDIATE RELEASE

October 18th, 2021

## Roll-2-Roll Technologies LLC announces new camera technology for web detection

### Roll-2-Roll Technologies introduces ODC Linear Camera product line for web guiding and monitoring  

**Stillwater, OK, October 18th, 2021** – Roll-2-Roll Technologies LLC is launching its line of single dimension cameras for web edge and contrast detection.  ODC Linear Cameras will replace the WPS line of sensor products for web guiding and monitoring, offering improved capabilities, and a cost effective alternative compared to traditional vision systems and laser profile solutions to the converting industry. The ODC Linear Cameras have already been shipped out to customers with applications that traditional sensors cannot provide a solution. 

**Features and Benefits of ODC Linear Cameras**

- New and improved CMOS line scan camera with high dynamic range
- Elimination of motion blur with a global shutter
- Up to 4x the scan rate compared to WPS
- Improved sensitivity to pick hard to sense materials and low contrast difference
- Same enclosure profile as the WPS line of sensor products. Low profile allows for placement in restricted spaces in converting lines where other sensors cannot be used.
- When combined with the soon to be released SCU6 controller, ODC  can provide 8x the dynamic range for superior edge detection and contrast detection
- Drop-in functional replacement to existing WPS products with same cabling

**Applications**

- Web guiding: Edge, line, center, pattern and contrast guiding
- Web width measurement
- Flag detection
- Registration mark detection
- Product length measurement
- Tear detection
- Simple automated defect detection

**Options**

ODC Linear Cameras are available with measurement ranges from 48 mm up to 768 mm. Light sources include: Infrared for mostly edge detection and high contrast applications, White Light (broadband) for visible contrast detection, and UV for fluorescent contrast applications. Additional LED light sources are available on request. Hardware camera resolution of 0.0635 mm (0.0025”) or 0.127 mm (0.005”). Higher firmware resolution of up to 0.015875 mm (0.000625”) available upon request. 

ODC Linear Cameras will work with existing SCU5 controllers with a firmware update. Two ODC 768 can be used with a single SCU5 controller to provide a total coverage of 1536 mm (60.5”). There are additional options and increased capabilities with the soon to be released SCU6 controller.

**Availability**

ODC Linear Cameras are now available for ordering and immediate delivery. 

Aravind Seshadri, President of Roll-2-Roll Technologies indicated: “Our commitment has always been to invest in research that will provide solutions to our customer’s problems; ODC Linear Cameras is a result of that commitment. We knew customers had issues with difficult to detect materials and they often used expensive camera systems to solve those problems. We came up with an inexpensive camera system that is easy to install and operate, and can be used with our existing controller platform.”

Online demos of the product and applications can be scheduled by contacting us through our website.

Roll-2-Roll Technologies LLC invites all converters and related industries to visit its website at [https://r2.tech](https://r2.tech) periodically to keep updated on new products and development, and its library of  instructional papers and videos.  

*Roll-2-Roll Technologies LLC provides the most advanced and simple to use web positioning sensor technology for the converting industry and general automation. The nimble technical company, we are the disruptors of the web handling industry for the benefit of our customers. *

# # #

If you would like more information about this topic, please contact Pedro Velasco at 405-726-0731 or email at marketing@r2r.tech. Visit the company website at [r2r.tech](https://r2r.tech) for additional resources, whitepapers and instructional videos.

---

# Roll-2-Roll Technologies LLC announces revolutionary All-in-One 1DC Sensor Series

URL: https://r2r.tech/news/roll-2-roll-technologies-llc-announces-revolutionary-all-one-1dc-sensor-series.md

Roll-2-Roll Technologies LLC announces the launch of its innovative 1DC Series of Roll-2-Roll® Sensors, setting a new standard for industrial sensing solutions. This groundbreaking all-in-one sensor combines advanced CMOS line scan technology with integrated processing power, eliminating the need for external controllers while maintaining exceptional precision across a wide range of applications and materials.

---

# Roll-2-Roll Technologies LLC announces revolutionary All-in-One 1DC Sensor Series

URL: https://r2r.tech/news/roll-2-roll-technologies-llc-announces-revolutionary-all-one-1dc-sensor-series-0.md

Roll-2-Roll Technologies LLC announces the launch of its innovative 1DC Series of Roll-2-Roll® Sensors, setting a new standard for industrial sensing solutions. This groundbreaking all-in-one sensor combines advanced CMOS line scan technology with integrated processing power, eliminating the need for external controllers while maintaining exceptional precision across a wide range of applications and materials.

The 1DC Series represents a significant advancement in industrial sensing technology, building on Roll-2-Roll's patented light scattering and spatial filtering technology. The 1DC sensor works effectively with virtually any material - from clear films and paper to metals and composites - delivering unmatched precision and versatility in a single compact device. 

**Features and Benefits of 1DC Series Sensors**

- Material Agnostic Performance: Functions flawlessly with clear, opaque, porous, nonwoven, metals, foils, and other materials
- Compact Construction: Easy installation in tight spaces with one-sided sensor design for simplified threading and reduced dust accumulation
- Integrated Light Source: Eliminates the need for external lighting equipment and fixtures
- High Precision: Hardware resolution as fine as 0.0635mm (0.0025in) with greater than 99.9% sensor accuracy
- Wide Sensing Range: Available in sizes from 96mm to 960mm
- Industrial-Grade Protection: IP67 rated (IP68 available on request) to withstand harsh industrial environments
- Universal Connectivity: Seamless integration via EtherNet/IP, PROFINET, EtherCAT, Modbus/TCP, and CC-Link IE Field Basic

**Applications**

- Edge Position Measurement
- Multiple Edge Position Measurement
- Center Position Measurement
- Line/Contrast Position Measurement
- Width Measurement
- Coating Width Measurement
- Multiple Strip Width Measurement
- Thread/String Counting
- Flag Detection
- Splice Detection
- Tear Detection

**Industries**

- Plastics & Film
- Paper & Converting
- Tissue and Towel
- Corrugated Board
- Battery Manufacturing
- Textile
- Nonwoven & Sanitary Products
- Flexible Packaging
- Tag and Label
- Tire & Rubber
- Metals & Foil

**Options**

1DC Linear Cameras are available with measurement ranges from 96 mm up to 960 mm. Light sources include: Infrared for mostly edge detection and high contrast applications, White Light (broadband) for visible contrast detection, and UV for fluorescent contrast applications. Additional LED light sources are available on request. Hardware camera resolution of 0.0635 mm (0.0025”). Higher firmware resolution of up to 0.015875 mm (0.000625”) available upon request. 

**Availability**

1DC Linear Cameras are now available for ordering. 

"The 1DC Series represents the future of industrial sensing," said Arvind Seshadri, President of Roll-2-Roll Technologies LLC. "By combining camera-like performance with sensor-like cost in an all-in-one package, we're giving manufacturers unprecedented capabilities without the complexity. The elimination of external controllers dramatically simplifies installation, reduces engineering time, and lowers the total cost of ownership while delivering superior precision across all materials."

Roll-2-Roll Technologies invites industry professionals to experience the capabilities of the 1DC Series firsthand at Converters Expo 2025 in Green Bay on May 21st, 2025. Attendees will have the opportunity to see live demonstrations and gain hands-on experience with this revolutionary sensor technology. For those unable to attend, online demonstrations can be scheduled by contacting the company through their website. For more information or to request a quote, please visit https:[//r2r.tech/request-quote](https://r2r.tech//r2r.tech/request-quote) or contact our sales team at sales@r2r.tech.

Roll-2-Roll Technologies LLC invites all converters and related industries to visit its website at [https://r2.tech](https://r2.tech) periodically to keep updated on new products and development, and its library of  instructional papers and videos.  

*Roll-2-Roll Technologies LLC provides the most advanced and simple to use web positioning sensor technology for the converting industry and general automation. The nimble technical company, we are the disruptors of the web handling industry for the benefit of our customers. *

# # #

If you would like more information about this topic, please contact Pedro Velasco at 405-726-0731 or email at marketing@r2r.tech. Visit the company website at [r2r.tech](https://r2r.tech) for additional resources, whitepapers and instructional videos.

---

# Roll-2-Roll Technologies LLC Awarded the John Matteucci Technical Excellence Award for 2017

URL: https://r2r.tech/news/roll-2-roll-technologies-llc-awarded-john-matteucci-technical-excellence-award-2017.md

AIMCAL presented two 2017 John Matteucci Awards for Technical Excellence and two Honorable Mentions. Aravind Seshadri of Roll-2-Roll Technologies LLC, Stillwater, OK, won the 2017 AIMCAL John Matteucci Award for Technical Excellence in Web Coating with his paper, “Predicting and Preventing Issues in R2R Manufacturing Using Data Analysis Techniques.”

---

# Roll-2-Roll Technologies LLC moves to its new facility on June 1st, 2017

URL: https://r2r.tech/news/roll-2-roll-technologies-llc-moves-its-new-facility-june-1st-2017.md

Web-handling systems provider Roll-2-Roll Technologies LLC will relocate to a new facility on June 1

---

# Roll-2-Roll Technologies LLC signs sales representative MetSource

URL: https://r2r.tech/news/roll-2-roll-technologies-llc-signs-sales-representative-metsource.md

Roll-2-Roll Technologies, a developer and manufacturer of intelligent web position sensors and web guides for the roll-to-roll and converting industry, has entered into a partnership with manufacturing sales representative firm MetSource, based in St Louis, Missouri.



MetSource, led by John Meyer, represents synergistic lines in the converting industry offering customer specific options bringing value to both customers and principals they represent.



MetSource will be an exclusive sales representative of Roll-2-Roll Technologies’ line of web guides and web positioning sensor products in the region of Missouri, Kansas, Arkansas, Oklahoma and Southern Illinois.

---

# Roll-2-Roll Technologies News Press Video

URL: https://r2r.tech/news/roll-2-roll-technologies-news-press-video.md

Roll-2-Roll Technologies is a new company operating out of the Center for Business Development at Meridian Technology Center.

---

# Roll-2-Roll Technologies Partners With ESPICE - Especialistas en la Industria de la Conversion y Empaque

URL: https://r2r.tech/news/roll-2-roll-technologies-partners-espice-especialistas-en-la-industria-de-la-conversion-y.md

Stillwater, OK-based **Roll-2-Roll Technologies LLC, **developer and manufacturer of intelligent web position sensors and web guides for the roll-to-roll and converting industry, announces its partnership with manufacturing distributor firm **ESPICE - Especialistas en la Industria de la Conversión y Empaque, **Tlalnepantla de Baz, México. ESPICE is a distributor of innovative web tension measurement and control products, and slitting systems in the converting industry.

---

# Roll-2-Roll Technologies partners with Fairfield Sales

URL: https://r2r.tech/news/roll-2-roll-technologies-partners-fairfield-sales.md

[Roll-2-Roll Technologies,](http://www.r2r.tech/) a developer and manufacturer of intelligent web position sensors and web guides for the roll-to-roll and converting industry, has announced its partnership with manufacturing sales representative firm Fairfield Sales for the Midwest region.

---

# Roll-2-Roll Technologies Partners with Power/mation

URL: https://r2r.tech/news/roll-2-roll-technologies-partners-powermation.md

Roll-2-Roll Technologies, a developer and manufacturer of intelligent web guide systems and web position sensors for the roll-to-roll and converting industry, has partnered with manufacturing distributor firm Power/mation of St Paul, MN, USA. Power/mation is a leading distributor of high-tech industrial automation solutions in the Midwest.

---

# Roll-2-Roll Technologies partners with TTS Systems

URL: https://r2r.tech/news/roll-2-roll-technologies-partners-tts-systems.md

Roll-2-Roll Technologies LLC, developer and manufacturer of intelligent web position sensors and web guides for the roll-to-roll and converting industry, announces its partnership with manufacturing distributor firm TTS Systems (Total Tension Solutions Ltd), of Wellingborough, UK. TTS Systems is a designer, manufacturer and distributor of web tension measurement and control products in the converting industry worldwide.

---

# Roll-2-Roll Technologies Revamps Brand with New Website, Logo

URL: https://r2r.tech/news/roll-2-roll-technologies-revamps-brand-new-website-logo.md

Roll-2-Roll Technologies LLC has unveiled a revamped website and new logo as part of a rebranding campaign designed to portray the company’s vision of simple to use solutions in converting.

---

# Roll-2-Roll Technologies Wins 2016 AIMCAL Technical Excellence Award

URL: https://r2r.tech/news/roll-2-roll-technologies-wins-2016-aimcal-technical-excellence-award.md

Roll-2-Roll Technologies Finalist – Coating ,Laminating, Metallizing Equipment Accessories The patented ARIS intelligent web-guiding system from Roll-2-Roll Technologies LLC (Stillwater, OK), combines fiber optic sensing technology with advanced signal processing and adaptive control technology. As a result, the system automatically detects the edge of the web without calibration or teaching and adapts to changes in web speed, tension, material properties and sensor gain. Capable of handling a wide range of materials and automatically adapting to new substrates or processes, the technology also enhances the flexibility of converting operations.

---

# Roll-2-Roll Technologies, Unilux Partner for Sales in Mid-Atlantic, Southern U.S.

URL: https://r2r.tech/news/roll-2-roll-technologies-unilux-partner-sales-mid-atlantic-southern-us.md

Roll-2-Roll Technologies LLC, developer and manufacturer of intelligent web position sensors and web guides, has partnered with Unilux to represent web guiding products in the Mid-Atlantic and Southeast regions of the United States.

---

# Ron Schmidt joins Roll-2-Roll Technologies Family

URL: https://r2r.tech/news/ron-schmidt-joins-roll-2-roll-technologies-family.md

Roll-2-Roll Technologies has announced that long-time industry veteran Ron Schmidt has joined the company as the Director of Sales.

---

# School Of Entrepreneurship Students, Teams Win More Than $27,000 At Governor’s Cup

URL: https://r2r.tech/news/school-entrepreneurship-students-teams-win-more-27000-governors-cup.md

A number of Oklahoma State University students and several teams from the Stillwater campus were among the winners during the 2013 Donald W. Reynolds Governor’s Cup Competition.

---

# Scott Meacham: Student Entrepreneurs Did Their Homework

URL: https://r2r.tech/news/scott-meacham-student-entrepreneurs-did-their-homework.md

I have a story. It’s the story of a handful of college students with remarkable focus and tenacity, a spinout technology from OSU, and $520,000 in Oklahoma-raised seed stage capital.

---

# Seedstep Angels Invests $100,000 As Part Of A $350,000 Convertible Note Round In Roll-2-Roll Technologies LLC

URL: https://r2r.tech/news/seedstep-angels-invests-100000-part-350000-convertible-note-round-roll-2-roll-technologies-llc.md

On July 25, Roll-2-Roll Technologies (R2R), a Stillwater-based company founded in 2013, issued $350,000 of convertible note securities. This transaction closed simultaneously with the issuance of $170,000 in common equity ($100,000 funded from Cowboy Technologies, and $70,000 from R2R management) for a total capital raise of $520,000. R2R is commercializing an advanced lateral guide for the roll-to-roll manufacturing industry that utilizes fiber optics to minimize the need for manual adjustment during product changeover. The company’s product will lead to a reduction in labor costs, downtime costs and product waste for those manufacturers who use it.

---

# Selection of Web Guides, cover story for June 2021 PFFC Digital

URL: https://r2r.tech/news/selection-web-guides-cover-story-june-2021-pffc-digital.md

The June 2021 Edition of Paper, Film & Foil Converter Magazine featured as its cover story the article "Properly Select a Web Guide for Your Operation" written by Aravind Seshadri, President of Roll-2-Roll Technologies. The article is based on our posts and articles "[Web Guide or Web Guiding Systems Overview](https://r2r.tech/articles/web-guides-or-web-guiding-systems-overview)," "[Web Guiding System: Why, What, Where and How?](https://r2r.tech/articles/web-guiding-system-why-what-where-and-how)" and "[Web Guide Selection and Installation Tips](https://r2r.tech/articles/web-guides-selection-and-installation-tips)"

---

# Spinning Off OSU Technology As A Startup: A Decade Of Work By Faculty And Grad Students Spawns A Business

URL: https://r2r.tech/news/spinning-osu-technology-startup-decade-work-faculty-and-grad-students-spawns-business.md

What makes a successful entrepreneur is a topic studied as much as in business schools today, including Oklahoma State University's Spears School of Business, as pinpointing genetic mutations responsible for disease is in biomedical research.

---

# Stillwater's Startup Roll-2-Roll Keeps Things Rolling At High Speed

URL: https://r2r.tech/news/stillwaters-startup-roll-2-roll-keeps-things-rolling-high-speed-0.md

Aravind Seshadri is talking diapers. Hundreds of millions of them. He’s focused on the way they are manufactured and the speed at which the material that becomes diapers flies through the machinery from one roll to another.

---

# Stillwater’s Startup Roll-2-Roll Keeps Things Rolling At High Speed

URL: https://r2r.tech/news/stillwaters-startup-roll-2-roll-keeps-things-rolling-high-speed.md

Aravind Seshadri is talking diapers. Hundreds of millions of them. He’s focused on the way they are manufactured and the speed at which the material that becomes diapers flies through the machinery from one roll to another.

---

# Three Teams Of OSU Students Win Top Prizes In Riata Business Plan Competition

URL: https://r2r.tech/news/three-teams-osu-students-win-top-prizes-riata-business-plan-competition.md

The fifth annual Riata Business Plan Competition awarded more than $43,000 in prize money on Saturday to help winning student teams finance their plans and turn them into viable business ventures.

---

# Tulsa, OSU-OKC Teams Win Governor’s Cup Small-business Prizes In Oklahoma

URL: https://r2r.tech/news/tulsa-osu-okc-teams-win-governors-cup-small-business-prizes-oklahoma.md

Student teams from Oklahoma State University-Oklahoma City, Rogers State University and Northeastern Oklahoma A&M College were recognized Thursday in the new small business division of the annual Donald W. Reynolds Governor’s Cup collegiate business plan competition.

---

# Web Guide Provides Next-generation Technology

URL: https://r2r.tech/news/web-guide-provides-next-generation-technology.md

Roll-2-Roll Technologies LLC (Stillwater, OK) rolls out ARIS, the next generation in web guiding technology.

---

# Web Guides: Monitoring and Knowledge - Cover Story for October 2021 Edition of PFFC

URL: https://r2r.tech/news/web-guides-monitoring-and-knowledge-cover-story-october-2021-edition-pffc.md

![Roll-2-Roll Technologies Sensors](https://r2r.tech/sites/default/files/inline-images/wps221family_1.jpg)



Page 4



The October 2021 Edition of Paper, Film & Foil Converter Magazine featured the article "Web Guide: The Evolution of Monitoring and The Need for Knowledge". The article written by Pedro P Velasco, COO of Roll-2-Roll Technologies is the cover story of this edition. Web detection has advanced to new sensor technologies with smaller footprint, multiple application capacity and greater sensing range. The future of web guiding requires the dissemination of knowledge through the industry. 



The article presents the recent advances in web sensing for guiding, width measurement and other monitoring applications.  



For more information on web guiding and monitoring visit our website to read more on the subject:



["Web Position Sensor Applications"](https://r2r.tech/applications/web-position-sensor-applications)  "[Web Guide or Web Guiding Systems Overview](https://r2r.tech/articles/web-guides-or-web-guiding-systems-overview)," "[Web Guiding System: Why, What, Where and How?](https://r2r.tech/articles/web-guiding-system-why-what-where-and-how)" and "[Web Guide Selection and Installation Tips](https://r2r.tech/articles/web-guides-selection-and-installation-tips)"

---

# WeGoLook Takes Top Honor: Overall Innovator Winner Inspects Products For Far-off Buyers

URL: https://r2r.tech/news/wegolook-takes-top-honor-overall-innovator-winner-inspects-products-far-buyers.md

WeGoLook won the overall award at The Journal Record’s Innovator of the Year event Wednesday.

---

# Winners Of The Donald W. Reynolds Tri-state Competition Named

URL: https://r2r.tech/news/winners-donald-w-reynolds-tri-state-competition-named.md

The Arkansas Economic Acceleration Foundation, an affiliate of The Arkansas Capital Corporation Group, is pleased to announce that R2R Technologies of Oklahoma State University of Stillwater, Okla., and Field Focus of Oklahoma State University of Norman, Okla., are the 2013 winners of the Donald W. Reynolds Tri-State Award in Las Vegas.

---

# Changing Roll Diameters and Web Edge Detection on Unwind and Rewind Guides

URL: https://r2r.tech/blog/changing-roll-diameters-and-web-edge-detection-unwind-and-rewind-guides.md

## Terminal web guides: The roll on my rewind stand changes diameter as it is fed from the converting line, does this affect the detection of the web on my rewind web guide?



#### Questions that our customers ask.



### A customer approached us because he was having trouble with the detection of the web by their terminal web guide on their rewind stand. 



As the material was fed from the converting line into the rewind stand, the diameter of the roll would increase and the distance from the web to the face of the sensor would decrease. This would cause issues with the effectiveness of the sensor.



### The main problem is that the web is experiencing a plane change. 



In order for any sensor to work properly, the web has to be stable. That is, the web must maintain the same plane throughout the entire run. When a plane change happens, the sensor will need to be repositioned or calibrated to account for the change in plane. ![](https://lh6.googleusercontent.com/AmItIj2VxByHznv2iUKdTZAsIb3E_sWOdypVuDSXj9_6pksBRw5zZkJjmxftffwMf-isMIl6SweqtqL_ZWiLzNecLkGtnXt-tLbgy3t77cFQWimMzrPljJF414FcAU-nhZwe99Nt)



So, in the case of a rewind or unwind stand, as the roll changes the diameter, the web is also changing the plane by increasing or decreasing the distance between the face of the sensor and the web.



### This is an easy fix. 



All it requires is a fixed idler roller installed on the machine frame for the rewind or on the shifting stand frame of the unwind. In both cases, the sensor would need to be installed after the idler roller on an unwind stand or before the idler roller on a rewind stand. Keep in mind that the idler roller on the rewind stand is fixed to the machine frame and the sensor is attached to the moving rewind stand. With the unwind stand, the idler roller is attached to the shifting stand of the unwind, while the sensor is fixed to the machine frame. As you can see in the diagrams below, the idler rollers help maintain the plane of the web with respect to the sensor face without regard to the diameter change of the unwind or rewind. 



![](https://lh6.googleusercontent.com/290vJh05c07kGXJFJcMBpFhxtK9r3dx_FBi2uxScL3gP49CzABx_RPSCps2b7hrZPR_w_5A3sw-1rMfn2aSDLdJg-2emJpccZgXUpIJ4HH5whjiGTbiekDr8moAw5GXQ_1x3XGa3)



![](https://lh6.googleusercontent.com/CXpBlk04A7in42ToadxvJAWFlPwxtu0IKm4oOqhaWmNnkUl-BHwd0hrT2ps-jUx1uF9-IIhfJpCbkPw6v6tpnui7MjO3lIK2_b6UIFT9Dh2QOESys4Y6clzS8zcIe05gQ8LSrDCM)



Most unwind and rewinds will come with this idler roller. However, machine builders or integrators that are building their first unwind or rewind, might overlook this requirement and build a unwind or rewind that does not include the idler roller. 



Another case could be a converter that is adding a web guide system to an unwind or rewind that was not originally fitted with one. Lack of experience with the fundamentals of web guiding, specifically in terminal web guides, might have them overlook the need for idler rollers in the design. This can also happen when converters are upgrading a current web guiding system that might require changing sensors, controllers and actuators. In this case, the problem might be installing the sensor in the wrong location.



In all three cases, the web will experience plane changes and the sensor will be ineffective in guiding the web as the roll changes diameter.



Having an idler roller that eliminates the effect of the changing roll diameter and properly positioning the sensor with respect to the idler roller is the solution to this problem.



If you liked the information in this blog post, [sign up](https://r2r.tech/contact?utm_source=blogpost11012021) to receive more information directly from us through our regular newsletter. 

---

# Contrast Guiding Application - Using a Continuous Edge Contrast to Guide or Monitor a Web.

URL: https://r2r.tech/blog/contrast-guiding-application-using-continuous-edge-contrast-guide-or-monitor-web.md

Another Option in Contrast Guiding when there is no Feature that could Mimic a Line.



In a previous post on contrast guiding we discussed [using the negative space between straight edged labels as an intermittent line](https://r2r.tech/blog/contrast-sensing-application-guiding-negative-spaces)that can be tracked by our sensor/camera and control system for web guiding applications. However, our system allows for other ways of using a contrast application that do not require a negative space that has characteristics of a line for the purpose of tracking.



A line used for tracking must have the same color hue and width so that it can be identified by the sensor or camera. The negative space between two rows of labels can be used as a line, as long as the negative space color hue and width remains the same throughout the entire length of the web. Sometimes we might be faced with tracking a contrast that is not defined as a line, such as when the width varies. One such case is when we laminate materials and we are interested in tracking the position of one of the materials. The example below shows two materials that contrast in color, black and white. This can be any color contrast as long as it is visible to the naked eye. We have several options for tracking the web. We can track the left edge of the white contrast from either the left side or the right side of the white contrast, or we can track the right edge of the black contrast from either the left side or right side of the black contrast.  



 ![](https://lh5.googleusercontent.com/_iHXPKBCyolb2C4U0QwJCUuZaIO-TYuuHwnENGZoEHq4kczNOAP8IQ624Q_Nf8RYHNSDpSU9SLb7LnJdeVHwDIyM69aI3sVKvCzOVd2iq4M8vaicbJNu7UToan7BMR5fWk_eaLXV)



Figure 1. Tracking the Edge of a Contrast



## Guiding on the Edge of a Color Contrast



Selecting the contrast color and the contrast edge orientation (left or right) is a matter of convenience. The operator would select the most effective option. In general, there are two options: right edge of a color or left edge of a color. However, you also have the option of which color is convenient for the application. As mentioned before, The example shown on Figure 1 above shows two possible color options to track, black or white. If you have several contrasts, for example multiple colors that run continuously in the machine direction, you can select any of the colors to track. 



## Setting Up the Controller for this Application



The [SCU5 controller](https://r2r.tech/products/roll-2-roll-controller) has an easy to access screen on the operator interface that allows us to teach the contrast mode and the contrast feature that we want tracked. 



![](https://lh4.googleusercontent.com/jsLxS1uV8qS1_6WLrhx72dAGLbA7fJMkAwtK_Gsh9eDFPmZyq8r_XycwFnhkTeI5GFk6xTHgJLXMtx_xAX7iKeyrkJJNG_PO3KEJDXpzqFR0ylCx35lhltTK-gnnW6Bw13pCSKhV)



Figure 2. Operator Sensor Screen in Contrast Mode



Figure 2 shows the Operator Sensor Screen in Contrast Mode with the teaching option on. This screen is accessed from the main operator interface screen by first selecting the advanced settings menu screen, followed by the operator settings screen and last the operator sensor screen. The step by step procedure can be found in the [SCU5 Sensor and Web Guide Controller User Manual](https://r2r.tech/sites/default/files/2020-03/SCU5_%20Sensor%20and%20Web%20Guide%20Controller%20User%20Manual%20v3.4_0.pdf), pages 22 through 27. 



The top horizontal bar shows the different contrasts that are visible to the camera at that moment. The operator can select the contrast to be tracked by highlighting the feature with the green border. The operator can change the feature to be highlighted by moving from feature to feature using the arrows on the right and left of the bar. In this particular example, the left edge of the white contrast in Figure 1 has been highlighted in green on the operator sensor screen shown in Figure 2. The contrast option shown on the screen indicates that it is set to track the right edge of a color, in this case the white color.



The Operator Sensor Screen is in teaching mode when the gear icon is green. Once the contrast mode and the contrast feature have been selected, the operator can press the gear icon to lock the teaching mode. The icon will turn red and the only contrast sensing option visible will be the one selected or taught (Fig. 3).



![](https://lh4.googleusercontent.com/N4JBUvRulXZoZvwzTg0wsD-mmPOt1AwBlUhHcpkpLQ9x_xqZ2OzCrc3BNaWDcM1Mc79D5doDb_0JEqSXkKfSJjysaz1BAGvXzV0JB7ChapRRjTgPbg7qTWvyYI9S-l0ovxI-75Pw)



Figure 3.- Contrast mode has been taught and locked



Once done, the operator can return to the previous screens using the return to previous screen button on the lower left hand side of the screen.



So now we know that we can guide a web by using a feature that has an edge that is constant and the color of the feature does not change. Additionally, this application allows for tracking a contrast from the right side or the left side, depending on the orientation of the material and the placement of the feature.



There are many applications in the converting industry that can benefit from this feature of our technology. Laminates can have a complicated pattern, but the contrast of the negative space at the edge can be used to guide or monitor the web without having to track the edge of the web. In Lithium Ion battery manufacturing we might not be interested in guiding, but in width control. The contrast application can be set up to monitor the width of a layer over another layer based on the contrasting colors of the materials. [We can always help you with your application](https://r2r.tech/contact) to look at alternative ways to control your converting process.




 You can [refer to the controller manual](https://r2r.tech/sites/default/files/2020-03/SCU5_%20Sensor%20and%20Web%20Guide%20Controller%20User%20Manual%20v3.4_0.pdf) for more information on the steps to set up a controller for such an application.

---

# Contrast Guiding Application - Using the Color Contrast Between Two Features

URL: https://r2r.tech/blog/contrast-guiding-application-using-color-contrast-between-two-features.md

A Very Special Option for Contrast Guiding and Monitoring



So far we have discussed using the negative space between straight edge labels to mimic an intermittent line and also using the edge of a label or contrast as a feature to track. Negative spaces tend to provide most of the opportunities for such applications, but we have seen that there are situations where the edge of a contrast can be used, as long as that contrast is constant.



However, there is a condition in contrast monitoring where a special application can be used.



The [SCU5 Controller](https://r2r.tech/products/roll-2-roll-controller) can be taught to track the threshold of two contrasting features. The condition is that each feature has to have a constant color and the orientation of the colors or contrast must also be constant.



|  |  |
| --- | --- |



Figure 1.- Color contrasts in different order




 As an example, let’s look at the two images above. Both have a sequence of red, black and yellow. However, the order differs between both. In the right image, the order from left to right is red, black and yellow. In the left image, the order from left to right is yellow, black and red. If we have set our controller to follow the threshold of the black and yellow on the left image, it would not track the threshold of the yellow and black on the right image, because it is in the wrong order. This special feature has limited uses, but is very useful in those limited applications.



As in previous set ups for contrast applications, you will need to access the advanced sensor setting screen to teach the controller. Figure 2 shows the application selected on the advanced sensor screen during the teaching mode. 



![](https://lh6.googleusercontent.com/oKGNw7ZiIHEJmApjNn4z6O185ckZvtX_50HMUBuhLsXa_DSVsqrE4FDMFgdGiSoDN_w6l256LXHCKntbhLv7MMlkZPRbTpa9zLjm_5cLr6kD6YcD2OcbHPioT1SgmCCoiL7KovMV)



Figure 2. Advanced Sensor Setting Screen



![](https://lh3.googleusercontent.com/V_fm47cZmU4zjaPfdVEBtjeZCmcoeMN6Ja72upHM6tzE1-LldQZKNq-v65Vzu4OW1Uy2esnYPDLbl53JixcuAOjtl5-TsyGTyRrssnojlJf2zSQLb4S72wi3RKEHKNRiS4C7Ump2)



Figure 3.- Advanced Sensor Setting Screen Set for Two Contrast Tracking



Additionally, as in previous posts, the feature selected will be highlighted in green on the top bar. The selection of the feature is done by changing the position of the highlight through the arrows on the top.



This application is useful when there are multiple contrast arrangements that can have the same colors available but in different order. Again, it is a very special application that is available to converters. 




 If you have a special contrast application that seems not to have a solution, [contact us and we will help you out](https://r2r.tech/contact).

---

# Contrast Sensing Application - Guiding on Negative Spaces

URL: https://r2r.tech/blog/contrast-sensing-application-guiding-negative-spaces.md

Contrast sensing allows for a variety of applications to guide or monitor your web. These applications help you eliminate the need for a printed line. Eliminating the printed line saves the cost of ink to print the line and the web material where the line would be printed. 



A contrast is any visible printed, embossed or laminated feature on a web. Most of the time, a visible feature is understood to be visible with the naked eye. However, it can include UV printed features that are not visible to the naked eye, but are detectable for a UV type of sensor or camera.



## Tracking a negative space between labels



There is one application where the web is guided by tracking a negative space in between labels. If the labels have straight borders and the width of the negative space is constant it is a simple application, as simple as line guiding.



![](https://lh5.googleusercontent.com/ydFFVoivrgYRw52KFqwYjQTAong-evENaUkLxWhgI2uMRy9PiWgSvMVq3VrSHafJLHPW6Mq3CGcVAexnt3Ck-0knNNgn5N9yVj75xCcXvVFDQeG3w3rJu2DNEk8tEssdUV9_KMNK=s0)



However, negative spaces can have variation of widths, especially when the label color matches the negative space color, or when the labels are separated by negative spaces. Sensors and controllers  using the current technology have issues with this situation. Typically, in a web guiding setting, the web guide will drift when the sensor loses track of the guiding feature. The sensor technology developed by Roll-2-Roll Technologies handles this situation and maintains the web aligned, even when there are breaks in the feature being tracked. 



![](https://lh4.googleusercontent.com/4_ml6S1hka8IMKmtmrHy7Ij5VpEsRGJMChOM5dtiAHp1nB0sb_58_Kl5oFmlDTXOea7sbNGUiV_oYROF6OrTbIUvEsteXJIOD2gklJSKZHWb6J2U9QV_IEASejLKTHhNsSGq9sxp=s0)



SCU5 Controller and Contrast Sensor Demo



## Teaching a Roll-2-Roll® Controller for Contrast Sensing



Teaching our controller to track a contrast is simple. When the operator is in the contrast sensing teaching mode he or she can select the option to follow a feature as if it is a line. Then they can select which feature to follow.

 ![](https://lh4.googleusercontent.com/tyeuR1FKq5LBX3NqbX_zlCLQJh9TrJwNHjPHAWIynULcS_oGNzIYajvyDh-O1HSrdX_cIPwlpNqIqokd4kU2WuB_TBNZevl-wfbghW-82uG0wPF1msKZksejb74XjlzN3AF37Pax=s0)

 ***Select a contrast tracking mode from the multiple modes available on the operator interface***



When the contrast mode screen is accessed, the operator can select one of the many contrast tracking modes by using the touch screen. Once the contrast tracking mode is selected then you can select the contrast feature to be tracked. The contrast feature is shown on the top of the screen.



![](https://lh6.googleusercontent.com/RnnSWnp-I6hCKswrd5jzFWjjNKnTRuzEH8PgFBb0C4Ki5tAyqxxzPtUPgtKWxFRHswsLJ2tSCw2auWqUYXmt67UWvYKedDXIWNZnXbpoD0RtKpmo15qU02nb-oQU6-zDOQ-jTG1e=s0)



***Select the tracking mode desired***



The contrast feature to be tracked is highlighted with a green border. If you need to change the feature to be tracked, you can highlight the feature by using the left and right icons on the top.



![](https://lh6.googleusercontent.com/SP_R78DA9Ogl_1Smxy7s4nDI3dfWDUMoah2ReyI_PlxbtuJTyNMWQRhH6Hx-DYKINSBY8UdWV3l87EZAqtJ97Pr1djp9Kv80Zce9jThfgzQEge4dX4TiR3Vj3Eyc6MsFMws6Zcpj=s0)



***Feature to be tracked***



![](https://lh6.googleusercontent.com/OumkYhmnfEwIiFXLqfzB2-ho4atrUMsZQC8PZcnoiknPt6wyEwjhRXawlUam5oUtGrhhv_P-cyrM-U41RcDn92jCbAWIEvl642yFQEhrPoncoq-vHofgwaxTTvcnsIgpUey9jA2O=s0)



***Feature to be tracked highlighted in green border***



We have a video that shows all the steps for contrast sensing application setups. [Click here to see the video](https://r2r.tech/videos/web-guiding-and-monitoring-contrast-sensing-scu5-controller-set-contrast-sensing?utm_source=blogsept222021)



 ![](https://lh4.googleusercontent.com/mSBLEknK4LDatTNqMndTpvFI7MR1uSFuyyu5ZNrzdO28yMFtDJ1rrRwnlYYwSWfuhIT7yv_7xvohrzwrbfqSEowXW8KMtMr-m9ITGHPSqQ004KRZIofxo-JTX7G7fu8DPdk7H5Sv=s0)



## Breaks in the contrast feature



One problem with contrast guiding using the negative space is the breaks in the space. This is caused by the separation of the labels. Most systems will drift when encountering such a problem, but not our [Roll-2-Roll Controllers®](https://r2r.tech/products/roll-2-roll-controller?utm_source=blogsept222021). Our controllers detect this break and will lock the position of the web guide where it last tracked the line. As soon as the line is within the sensor range, it will track the line again. This happens because our system is programmed to only track a line that has the same width and color hue that was selected during the teaching mode and to lock the web guide in its last position when the width or color hue parameters have changed. 



In our example above the space between the labels would be visible to the sensor until the color of the label is the same as that of the line. At that point, the controller would lock the position of the web. Once there is any color difference between the negative space and the label, the system will resume tracking the feature that was selected in the teaching mode.



There are many other applications in contrast sensing that we will discuss in future posts. If you are interested in learning more about contrast sensing and applications,[sign up for our monthly newsletter.](https://r2r.tech/contact?utm_source=blogsept222021) This will give you access to many of the applications, webinars and other instructional materials as they become available.

---

# Contrast Sensing Applications - Guiding and Monitoring for Converting

URL: https://r2r.tech/blog/contrast-sensing-applications-guiding-and-monitoring-converting.md

## Features on the surface of the web as a detection target in Contrast Sensing



Contrast sensing relies on detecting a feature on the surface of the web. This feature can be printed, laminated or embossed. This is a great application when the printed, laminated or embossed features are relevant to the positioning of the web instead of the edge of the web.



### Slitting operations are good examples of how a contrast sensing application is used. 



When slitting a printed web, the location of the print on the resulting rolls is of great importance. In many cases, the printer will add a line to be used as a guiding reference. The sensor tracks the location of the line. This information is used by the web guide system to reposition the web based on that line. This specific application is known as line guiding.

 ![Line guiding](https://r2r.tech/sites/default/files/inline-images/lineguidingemptyspavr_0.jpg)

However, there are many other ways that contrast sensing applications can be used. It is possible to guide based on features of the printed web. This allows for multiple options in guiding. Granted, not all available technologies can do this, but we can.

 ![Contrast Sensing Applications](https://r2r.tech/sites/default/files/inline-images/Untitled%20presentation%20%283%29.jpg)

### Applications



Contrast sensing can also be used to measure and/or monitor width. It is possible to measure the width of a material that is laminated within another material. The width of an overlap can also be measured and monitored. All this allows for greater control of the converting operation.

 ![Width measurement system with contrast sensors](https://r2r.tech/sites/default/files/inline-images/137334000014634016_zc_v14_1619733392696_wps_221_contrast_sensors_for_width_measurement.jpg)

Contrast sensing can also be used to detect intentional marks on the web. This can be used to monitor speed of a web, mark defects, 





All the options above have addressed detecting a printed feature. This does not have to be the limitation. Embossed features, intentional changes on the web construction or event ridges can be used for the purpose of contrast sensing applications. In general, if you can see it with the naked eye, it is probable that it can be detected by our contrast sensing application. So, selvages on textiles, one specific line printed within other lines, edges of labels, uv markings and lines, ridges on surfaces or materials laminated within films are all possible. [We can help you determine a solution](https://r2r.tech/contact?utm_source=blog7-19-2021) with contrast sensing today!








  

---

# How does the Roll-2-Roll® Sensor compare to a vision system

URL: https://r2r.tech/blog/roll-2-roll-sensor-vs-vision-system.md

In our [previous blog post](https://r2r.tech/blog/roll-2-rollr-sensor-just-sensor) we looked at how [Roll-2-Roll® Sensor](https://r2r.tech/sensors) is more than just a sensor and is similar to a camera based vision system. In this post we will look at how it actually compares to a traditional camera based vision system.



## Traditional camera based vision system



Vision systems typically have a dedicated camera, independent light source, frame grabber and a dedicated computer to process the image. These systems are typically used for defect detection. The part to be inspected is illuminated using a lighting module that controls the amount of light falling on the object. The image of the illuminated object is captured by a high speed camera equipped with traditional lens optics. The timing of the capture is typically synchronized with a trigger from a PLC (programmable logic controller), a registration mark signal, or a rotary encoder. The image captured by the camera is sent to a real-time processing system through a high speed data transfer interface with or without a frame grabber. The digitized image is then processed in the real-time hardware (essentially a computer) that runs digital signal processing algorithms for inspection and defect detection. The raw and processed image is also displayed by a monitor which provides the user interface between the real-time hardware and the operator. Based on the application four main types of inspection are carried using the captured image: (1) dimensional quality, (2) surface quality, (3) structural quality and (4) operational quality. A rejection mechanism actuated by the PLC is used to reject the parts that are identified as defective by the machine vision system.

 ![Traditional machine vision system - more complicated than a simple sensor](https://r2r.tech/sites/default/files/inline-images/Machine-Vision-System_0.png)

## Disadvantages of vision systems



Vision systems are ideal for certain applications with some specific requirements. However, a vision system is not the ideal choice for all inspection applications. The two main drawbacks of the vision systems for simpler inspection applications are: cost and user friendliness.



### Cost



The traditional vision systems are ideal for inspecting high value products at high speeds. When the process conditions are fixed these system provide reliable performance with high throughput. However, because of the individual component cost and complexity, these systems are expensive. Additionally, these systems require an "expert" to program; which increase the overall cost of ownership of the system.



### Lack of user friendliness



One of the main drawback of these vision systems is their lack of user friendliness. Since an expert is needed to program the vision system, it is often not operator friendly. These system can cause significant downtime in processes with frequent product changeover since they need to be calibrated whenever the operating conditions change. Often a "non-user expert" is needed to make the changes.



## How does the Roll-2-Roll® Sensor Compare?



For certain inspection applications, the [Roll-2-Roll® Sensor](https://r2r.tech/sensors) can compete with traditional vision systems. In fact any of the [Roll-2-Roll® Sensors](https://r2r.tech/sensors) with the [Controllers](https://r2r.tech/products/scu5-controller) can provide complete inspection solution for certain applications including web width measurement, string/thread counting application, multiple strip width measurement application, hole/void or tear detection, flag detection, etc. For these applications the [Roll-2-Roll® Sensor](https://r2r.tech/sensors) has the following advantages.



### Low Total Cost of Ownership



Unlike the traditional camera based system, the [Roll-2-Roll®](https://r2r.tech/sensors) sensing system includes two main components: the sensor head and the controller. The light source, optics and the camera are all enclosed in a single package while the processing is done by the controller. Overall this significantly reduces the initial purchase cost of the system by eliminating the need for separate light source, expensive fixturing or gantry build, dedicated capturing system and the processing computer. Without the need for a "vision expert" the overall cost of ownership is also significantly reduced. 



### Simple to Use



[Roll-2-Roll® Controllers](https://r2r.tech/products/scu5-controller) are simple to use and operate. There is no programing involved and the system is completely parameterized for ease of use by an operator. Unlike camera based systems, our systems are completely customized for each application. This customization enables ease of use especially with frequent product changeovers.



## Conclusion



There are certain applications where a traditional camera based visions systems are the ideal choice. However, for some simpler inspection applications the [Roll-2-Roll® Sensors](https://r2r.tech/sensors) and [Controllers](https://r2r.tech/products/scu5-controller) are a compelling alternative. If you converting operations requires web width measurement (slitting, blown film, folding, shrink sleeve), mark detection (spray, glue, registration), flag detection (defect flag detection), string or thread counting, multiple strip width measurement, tear detection, etc., [Roll-2-Roll® Sensors](https://r2r.tech/sensors) and [Controllers](https://r2r.tech/products/scu5-controller) offer an unique value proposition with a quick return on investment. Any company can now afford a low cost inspections system which does not require "vision experts" for implementation and maintenance. Please [contact us](https://r2r.tech/contact) so that we can help solve your inspection challenges with a compelling alternative to vision systems.

---

# Is Roll-2-Roll® Sensor just a sensor?

URL: https://r2r.tech/blog/roll-2-rollr-sensor-just-sensor.md

It is more than a sensor, in fact it is a line scan camera. [Roll-2-Roll® Sensors](https://r2r.tech/sensors) are more than just a typical sensor, they are one-dimensional line scan camera with integrated lighting and optics. From [WPS 48](https://r2r.tech/products/sensors/wps-48)(https://r2r.tech/products/wps-48) to [WPS 900](https://r2r.tech/products/sensors/wps-900)(https://r2r.tech/products/wps-900), all the sensors have one dimensional imaging element (pixel array), one dimensional imaging optics ([the patented fiber optics](https://r2r.tech/articles/impacts-latest-developments-sensing-technology)) and a one dimensional integrated LED lighting (IR, UV or white light). For example the [WPS 48](https://r2r.tech/products/sensors/wps-48)(https://r2r.tech/products/wps-48) has 768 pixels with a pixel resolution of 0.0635 mm or 0.0025" with a total 1-D camera range of 48.768 mm or 1.92". Similarly the [WPS 900](https://r2r.tech/products/sensors/wps-900)(https://r2r.tech/products/wps-900) has over 14,000 pixels at a resolution of 0.0635 mm or 0.0025" with a total 1-D camera range of 901 mm or 35.47". 



![Exploded view of the sensor showing the optics, lighting and line scan camera.](https://r2r.tech/sites/default/files/inline-images/SensorAssembly-Exploded-View-of-LineScan.png)



## How does it work?



The working of the sensing system is similar to any camera based vision system. The [Roll-2-Roll® Sensors](https://r2r.tech/sensors) act as a camera and the image captured by the camera is processed by the [Roll-2-Roll® Controller](https://r2r.tech/products/roll-2-rollr-sensor). In fact the sensors by themselves do not have any intelligence, they only have the hardware (lighting, optics and imaging). The controller is the one that triggers the lighting and image capture sequence. And once the image is captured, the image is transferred and processed by the controller. 



## What is the advantage of such a system?



One of the biggest advantage of the system is the modularity. Modularity helps reduce upgrade cost, replacement cost and overall cost of ownership. 



### Reduction of upgrade cost



Since the controller is the brain behind the vision system, most upgrades can be done without changing the sensor (lighting, imaging and camera) hardware. Hence the upgrade cost just involves the upgrade of the controller which is significantly lower, especially with wide band sensors ([WPS 221](https://r2r.tech/products/sensors/wps-221)(https://r2r.tech/products/wps-221), [WPS 440](https://r2r.tech/products/sensors/wps-440)(https://r2r.tech/products/wps-440) and [WPS 900](https://r2r.tech/products/sensors/wps-900)(https://r2r.tech/products/wps-900)). 



This upgrade of the controller includes firmware upgrades to add functionality as well as hardware upgrades to increase processing speed. And both of these could be done by just swapping the controller in the field with minimal downtime.



### Reduction of replacement cost



The modular design also reduces the replacement cost of the parts. Unlike the sensors with the controller built-in, the whole system need not be replaced if and when a damage occurs. Only the damage component can be replaced with significant savings.



### Reduction of overall cost of ownership



For large customers and OEMs who use multiple sensors (sizes) and controllers (for different applications), the overall cost of ownership is lower since they can mix and match the sensors and controllers. A sensor and controller used for one application can be readily repurposed for a completely different application. For example, a sensor and controller used for web guiding and edge detection can be repurposed to inspect fibers. Similarly a sensor used for flag detection can be repurposed for registration mark detection. This significantly reduces the cost of ownership since the sensor and controller can still be repurposed for any application after the purchase date. 



## So why do we call it a sensor?



Even though the [Roll-2-Roll® Sensors](https://r2r.tech/sensors) is actually a vision system with advanced sensing capabilities, we call it a sensor because it is so simple to use just like a sensor. We strongly believe in the quote attributed to Leonardo da Vinci



> simplicity is the ultimate sophistication



We want to provide a simple solution to our customers so that they can focus on their problems rather than trying to understand a complex vision system. 

---

# Issues in Negative Space Web Guiding

URL: https://r2r.tech/blog/issues-negative-space-web-guiding.md

## Issues in Negative Space Web Guiding as Substitute for Line Guiding 



In a previous post we presented the concept of negative space web guiding as an option to line guiding. We are talking about using the negative spaces between printed features, such as the separation between labels. This application does come with its challenges.



![Negative Space Web Guiding](https://r2r.tech/sites/default/files/inline-images/ARIS-WPS-WL-48-Contrast-Sensing_0.png)



## Consistency of the negative space



As with any line, the negative space must maintain the width and hue throughout the entire run. It cannot be efficiently tracked by the sensor if it varies in width or color tone, as the sensor will consider it a different line.



## Negative space in the cross machine direction



Guiding a web using the negative requires that the negative space is available in the cross machine direction. As with line guiding, the line is tracked as it passes in front of the face of the sensor.



## Intermittent negative space



Negative species can be constant or intermittent. Intermittent spaces occur when there are breaks on the space, such as when labels are separated in both machine and cross-machine direction. They are treated as intermittent lines. 



## Gradients around the negative space



There are labels that do not have a defined edge of the same color. Typically, you find labels that have a border, sometimes a very fine line of the same width and color. However, there are cases where not only does the label not have a border, but also has color gradients that might even blend into the negative space.



![Negative Space in Labels](https://r2r.tech/sites/default/files/inline-images/Untitled.jpeg)



##  



##  



##  



##  



## Web flutter



In any contrast sensing application, including line guiding, the web has to be stable. This means that there is no flutter as the web passes in front of the sensor. When a web flutters, the changes in the web plane will cause issues in detecting the line or contrast. This in turn hinders the [web guiding performance](https://r2r.tech/blog/web-guiding-fundamentals-web-guiding-performance). The solution for web flutter affecting detection by the sensor is the use of a back-up idler roller. The sensor is positioned so it looks at the web as it passes over the idler roller face. Idler rollers with a dark face cover or coating are mostly used for contrast applications.



With all these issues it seems that guiding off a negative space is not a simple task. Well, it isn't. However, we will discuss in depth some of these issues and solutions to them that will allow you to use the negative space as a line guiding option in future posts  .



[Contact us](https://r2r.tech/contact) if you have a challenging application or are interested in more information on web guiding and monitoring.

---

# Line Guiding with WPS Sensors 

URL: https://r2r.tech/blog/line-guiding-wps-sensors.md

> Slitting a roll of printed labels or even monitoring the label printing process, you just might need a line or contrast sensing application for guiding.



One of the great features of the [Roll-2-Roll® Sensor](https://r2r.tech/products/roll-2-rollr-sensor?utm_source=blog01112021) for contrast sensing is the wide variety of applications it offers. The sensor coupled with the [SCU5 Roll-2-Roll® Controller](https://r2r.tech/products/roll-2-roll-controller?utm_source=blog01112021) allows the operator to determine the application required for web guiding, width measurement or monitoring. 



## Line guiding



Based on the light source in the sensor, you can detect a simple printed line of any width that is within the sensing range of the sensor and no less than 1 mm. If the contrast is very high, both infrared and white light sensors can detect the line. For more challenging contrasts, it is recommended to use the white light sensor. If the line is printed with UV ink, then the sensor with UV light source is recommended. 



One of the benefits of the WPS sensors for line guiding applications is the ease given to operators to set up the control for this application. Through the operator interface the operator can go to the control operator screen and select the sensor mode between edge and contrast by pressing one button. In this same screen, the operator can select the feature on the web that is to be tracked. The operator can select to track:



- A feature that resembles a continuous line
- The threshold between two contrasting features
- The threshold of an individual feature.



You can see a video of how this done here.



### Line guiding on a continuous line



Line guiding is based on tracking a feature that resembles a continuous line. The continuous line is determined by the width and the hue of the feature. So, even though our thought goes directly to thinking of a printed line, it can also be used to track the empty space between two labels printed on a web. If the background is white and we have two or more lines of labels that have a constant separation between them, you can set the sensor and controller to track the white space between the labels. This white space can be used as a wide line that the sensor can track.

 ![Line guiding on a feature - continuous line](https://r2r.tech/sites/default/files/inline-images/lineguidingemptyspavr.jpg)

Thresholds of features can also be used for line guiding with the Roll-2-Roll® Sensor. In this case, the threshold between two distinct features can be treated as a very thin line. As long as the characteristics of the two features are maintained, the sensor and controller will detect the threshold. For web guiding purposes, the controller will process the image captured by the sensor and provide the output to actuate the web guide mechanism.

 ![Line guiding on a feature - two contrast thresholds](https://r2r.tech/sites/default/files/inline-images/contrast.jpg)

A threshold of a single feature could be the case where the feature is constant, but the contrasting side is not. An example of this could be labels that have multiple colors on a white background of the web. In this case we would set the edge of the white background as the threshold to track. 

 ![Line guiding on a feature - one contrast threshold](https://r2r.tech/sites/default/files/inline-images/singlefeatureedgeguiding.jpg)

Now, one of the questions that arises when we explain these applications is, what happens with lines that are intermittent, such as the ones created by the empty space between labels? Does the sensor lose the line tracking in these voids? Actually, it does. But, the controller accounts for this by processing the information from the sensor and re-tracking the line every time the sensor sees the feature with the same characteristics it was taught by the operator. The characteristics are width and hue. In the case of web guiding by following a line, every time the sensor does not see the features the operator taught the controller, the web guide stops at that point until the sensor sees the same feature again. So, with an application that is guiding a web of printed labels, the speed of the web makes it look like it is processing a continuous line instead of an intermittent line, due to the speed of the web. 



Now, contrast sensing can be used for width measurement and monitoring. In my next blog post we will address this application using Roll-2-Roll® Sensors. 



**If you like this post and are interested in keeping up with our developments and applications, [contact us and sign up](https://r2r.tech/contact?utm_source=blog01112021)for our monthly email edition. We have tons of web guiding and monitoring knowledge that we would like to share with the converting industry. Better yet you can [schedule a live demo](https://r2r.tech/schedule-live-demo?utm_source=blog01112021)of our product line based on your particular application.**

---

# Negative Space Web Guiding - Consistency of the negative space

URL: https://r2r.tech/blog/negative-space-web-guiding-consistency-negative-space.md

# In negative space web guiding dealing with the consistency of the negative space is the same as if we were dealing with the consistency of a printed line for line guiding. 



The line has to be of the same width and color in order for the sensor to track it. Any variation and the sensor will not recognize it. The same thing happens when using the negative space as guiding feature.



## Negative spaces in the cross machine direction are lines formed by a non-printed area.



In the graphic below we can see how these are formed from the borders of printed features, such as the edges of labels.  

 ![Lines Created by Negative Spaces](https://r2r.tech/sites/default/files/inline-images/NegativeSpaceline.png)

The negative space is consistent in its hue or color tone. It is white, which is the background of the web on which the labels are printed. However, we can see in the graphic that the width is has some consistency issues.

 ![Negative Space Inconsistencies](https://r2r.tech/sites/default/files/inline-images/Inconsistencies.png)

The graphic above shows two of the most common width inconsistencies dealing with negative space web guiding: irregular edges of printed labels and breaks by negative spaces in between printed labels.



## Dealing with irregular label edges will require a special application of contrast guiding.



In this case it might be simpler to look for another printed feature to guide off. For example, we can see the labels on the right side have a curved edge on the left side and a straight edge on the right side. Of course, the labels have different color hues, but they do have a straight edge that is next to a negative space. There is a web guiding solution for guiding off this feature which we will talk about in a future post. 



> Interested in this solution right now? Don't wait and contact us right now to help you out



## Space between labels in the machine direction



When dealing with negative spaces created by separation of labels, such as seen on the graphic, we can see that the negative space line would lose the consistency of the width on each of these breaks. In a sense, it is an intermittent line. Additionally, we can see the labels on the left side of the graphic have a degradation. As the degradation gets closer to the hue of the negative space, the tracking sensor might interpret this as a widening of the negative space. The sensor would quit tracking the negative space as it would consider it different than what it was calibrated for. Of course, we also have a solution for this particular issue, and as before we will address these solutions in a future post.



> You can contact us right now if you require inmediate assistance with a similar application or any other issue width tracking printed features on a web.

---

# Negative Space Web Guiding - Using the Negative Space in your Print 

URL: https://r2r.tech/blog/negative-space-web-guiding-using-negative-space-your-print.md

## Line guiding is one of the subsets of contrast sensing applications.



It requires the printing of a line on a web. It's purpose is to provide a feature that a sensor can track to determine the web position. The typical use is in web converting where guiding on the edge might not be a precise parameter in printing labels. However, printing a line is an additional cost. After all, it is additional ink. If the line is printed outside of the main printed features of the web, it could be leaving money in the converting floor in the form of excess trim on the edges of the web. This is particularly expensive in labels printed on foil, a costlier material than paper. Here is where using the negative space in the print could be a solution to reduce costs in your printing operation.



## Negative Spaces 



Negative space is the background or the area that surrounds the subject of the work. Labels are printed features on a web. The background is considered the negative space. In many cases the negative space is a constant color or hue. In these cases where the background color has no degradation or changes in color, contrast detection can be used for a Negative Space Web Guiding



## Negative Space Web Guiding 



A desired condition for contrast detection is a feature that is constant in width and in color tone. Line tracking is such and application. If the line maintains the color tone and its width, it is easily tracked. Line guiding is based on that. The same can be applied in using a negative space as a feature to track. If the negative space is of constant width and color tone, then it can be used as feature to track, and therefore can be used as negative space web guiding. That is easy when the space is constant. What if the feature is intermittent?

 ![Contrast Tracking with Intermittent Negative Space](https://r2r.tech/sites/default/files/inline-images/ARIS-WPS-WL-48-Contrast-Sensing.png)

> #### You really do not need to add a printed line to your roll of labels to track the position of the labels. Negative Space Web Guiding is an interesting solution to eliminate line printing for web guiding. Negative Space Web Guiding is a solution to this. However, intermittent negative spaces can be an issue for accurate and precise web guiding. Well, we have a way of treating with intermittent negative spaces. Our technology allows our contrast sensors and our line of single dimension cameras to give you a solution that allows many applications using negative spaces, including when they are intermittent. 



Our next blog will explain some of these applications and how they can help your operation deal with interesting ways of using negative spaces. [Contact us for more information on web guiding and monitor applications](https://r2r.tech/contact).

---

# New Technologies in Web Width Measurement 

URL: https://r2r.tech/blog/new-technologies-web-width-measurement.md

## Web Width Measurement - an Important Quality Parameter



Web width measurement is one of those applications that is usually an afterthought until reality bites. Converters might be faced with improving their process by reducing web edge trim or eliminating downtime due to web widths out of specification. Most importantly, they want their customers to be happy by avoiding delivering products that do not comply with customer web width requirements. 



The industrial world knows that having a customer that trusts your product is one of the greatest assets. If your width monitoring process allows you to avoid delivering out of specification rolls, you will definitely have a satisfied returning customer. So, how can we help you in achieving satisfied customers? 



## Different Widths in the Same Converting Line - How converters currently deal with it.



When handling different web widths in the same converting line, the issue is having sensors that provide enough coverage. Typically you have two sensors and then you adjust their position to allow the sensors to see both edges of the web. This repositioning of sensors can be manual or electromechanical. 



### Manual Repositioning of Sensors



In manual repositioning an operator has to physically access the sensors and move them to the new position, calibrating the sensors to adjust for the change, and then estimate the actual distance between the sensors to provide a reference for the width measurement. In this system, there are issues of accuracy of the measurement, time lost in repositioning the sensors, and wear and tear of the equipment.



### Electromechanical Repositioning of Sensors



With electromechanical repositioning an actuator moves the sensors to their positions. It still requires spending time to calibrate the sensors, move the sensors to the position required and verifying that it is the proper distance. In this case, the electromechanical system is a costly system, the sensors still require calibration, and the wear and tear still exists causing maintenance or replacement costs, along with loss of accuracy and precision.



## Solving the Sensor Repositioning Issue



### A Two Sensor Solution



One solution for this problem is to have two sensors that have a wide enough sensing range that allows handling different widths without having to reposition the sensors. You would still have to deal with sensor calibration, but the elimination of sensor repositioning might be enough. However, adding a system that does not require calibration certainly provides a great bonus to the application.



### A Single Sensor Solution - is it possible?



A second solution would be a sensor wide enough that would cover the entire width of the web. Sensor repositioning is eliminated completely, even though sensor calibration is still required.



### Our Solution - Wider Sensing Ranges and No Calibration



[We have a solution to all these problems.](https://r2r.tech/applications/web-width-measurement-and-monitoring?utm_source=blognov10) Ever since we launched our technology in the Converting industry, our main differentiator has been our sensor technology. We are able to offer a sensor that has multiple applications, with a very manageable number of models based on sensing ranges and light sources. Any of our sensors can be used for width measurement and monitoring by the edge of the web or a constant contrast within a web, such as a printed line. Better yet, our sensors do not require calibration, so you can use them on any material.



The single sided sensor compact design provides the converter with a sensors that is not subject to space restraints. Unlike fork style sensors, webs with greater material thickness are not an issue.



### An Example of a Specialty Web Width Application with our Technology



We prepared a web width measurement and monitoring application for a customer in North Carolina that required a contrast sensing application to measure and monitor the width of a web within a clear coating. You can [read more about this application in our website.](https://r2r.tech/testimonials/width-measurement-and-monitoring-cotton-bale-bag-manufacturing-using-contrast-sensing)



### WPS 900 - The Widest Sensing Range in the Industry Provides a Single Sensor Width Measurement Solution



We recently launched [WPS 900 sensor.](https://r2r.tech/products/wps-900-sensor?utm_source=blogonwidthmeasurement) At a sensing range of 900 millimeters (35.4 inches) it provides the widest sensing range in the industry. This means you can use a single sensor for center guiding or width measurement or both, for any width of material up to 35 inches. More important, its design provides a resolution of .127 mm or .005 inches, and allows you to monitor up to 256 different edges.



If you are interested in a width measurement application, [schedule a live online demonstration from the comfort and safety of your office.](https://r2r.tech/schedule-live-demo?utm_source=blognov10) If you would like to know more of our web guiding and monitoring applications, contact us to get our monthly ENews and other information as it becomes available.



Future topics: Edge curling, how it affects width measurement and what you can do about it.

---

# ODC Linear Camera product line - replacement of the WPS Sensor product line

URL: https://r2r.tech/blog/odc-linear-camera-product-line-replacement-wps-sensor-product-line.md

## The new ODC Linear Camera system for web edge and contrast detection and monitoring



We took another step forward in advancing the web handling technology for the converting industry. Now converters can benefit from using affordable vision systems for web guiding and monitoring. These last couple of months we finalized the introduction to the market of the ODC Linear Camera system for web edge and contrast detection. It will replace the tradition WPS line of sensor products from Roll-2-Roll Technologies LLC, and customers have already been notified of the end of life of the sensor line. This includes the guarantee that service and support will be available for the WPS sensor line until 2025.



ODC Linear Cameras are single dimension cameras for web edge and contrast detection. They will have the same compact enclosure design of the WPS Sensor product line allowing for placement in spaces that fork style sensors and other vision systems cannot be placed. Designed for web guiding and monitoring, ODC Linear Cameras offer improved capabilities, and a cost effective alternative compared to traditional vision systems and laser profile solutions to the converting industry. The ODC Linear Cameras have already been shipped out to customers with difficult applications for which traditional sensors have no solution. 

 ![ODC Linear Camera](https://r2r.tech/sites/default/files/inline-images/Email%20Signature%20Q4%202021.jpg)

**Features and Benefits of ODC Linear Cameras**



- New and improved CMOS line scan camera with high dynamic range
- Elimination of motion blur with a global shutter
- Up to 4x the scan rate compared to WPS
- Improved sensitivity to pick hard to sense materials and low contrast difference
- Same enclosure profile as the WPS line of sensor products. Low profile allows for placement in restricted spaces in converting lines where other sensors cannot be used.
- When combined with the soon to be released SCU6 controller, ODC  can provide 8x the dynamic range for superior edge detection and contrast detection
- Drop-in functional replacement to existing WPS products with same cabling



**Applications**



- Web guiding: Edge, line, center, pattern and contrast guiding
- Web width measurement
- Flag detection
- Registration mark detection
- Product length measurement
- Tear detection
- Simple automated defect detection



**Options**



ODC Linear Cameras are available with measurement ranges from 48 mm up to 768 mm. Light sources include: Infrared for mostly edge detection and high contrast applications, White Light (broadband) for visible contrast detection, and UV for fluorescent contrast applications. Additional LED light sources are available on request. Hardware camera resolution of 0.0635 mm (0.0025”) or 0.127 mm (0.005”). Higher firmware resolution of up to 0.015875 mm (0.000625”) available upon request. 



ODC Linear Cameras will work with existing SCU5 controllers with a firmware update. Two ODC 768 can be used with a single SCU5 controller to provide a total coverage of 1536 mm (60.5”). There are additional options and increased capabilities with the soon to be released SCU6 controller.



**Availability**



ODC Linear Cameras are now available for ordering and immediate delivery. 



Online demos of the product and applications can be scheduled by [contacting us through our website](https://r2r.tech/contact?utm_source=blogpost10202021).



Roll-2-Roll Technologies LLC invites all converters and related industries to visit its website at [https://r2.tech](https://r2.tech) periodically to keep updated on new products and development, and its library of  instructional papers and videos.  

---

# Old web guiding system no longer operational - what can you do?

URL: https://r2r.tech/blog/old-web-guiding-system-no-longer-operational-what-can-you-do.md

Many converters face the issue of an old web guide system no longer operational. In many cases the units are so old that the manufacturer no longer exists or has been bought out. In other cases, the manufacturer no longer supports the model that you have.

 ![Old web guide system no longer operational - North American Web Guide](https://r2r.tech/sites/default/files/inline-images/NorthAmericanUpgrade_0.jpg)

In general the issue is not with the mechanical components of the web guide system. These are usually rollers, bearings, shafts, linkages and other mechanical elements that can be found off the shelf or can be manufactured. The real issue comes from the sensors, controllers and actuators.



## The options available to the converter



Our experience with converters facing this problem narrows the options to three: Do-nothing, buy a complete new web guide system, and upgrade the current system with the necessary components.



## Do nothing



This is one of the most commonly adopted options, but it can carry some costly drawbacks. “Do nothing” means you adapt to the problem and live with it. In the case of converting lines, it means placing the web guide in the servo center position, and locking it in that place by turning it off. Some converters go as far as removing the web guide completely. The implications are that there will be additional material scrap in the process or in the final product, along with downtimes to reposition rolls or adjust the web position. If you recall [our series on web guiding fundamentals](https://r2r.tech/blog/web-guiding-fundamentals-why-we-need-web-guides?utm_source=blog03012022) and our article on web guiding systems, [why, what, where and how?](https://r2r.tech/articles/web-guiding-system-why-what-where-and-how?utm_source=blog03012022), web guides are used in converting lines, even when new because materials, machines, processes and operators are not perfect. Any one of these will cause spoilage, and cost money. However, some operations are willing to live with this, up to a certain point.



## Buy a new web guide system



This option is the most expensive, but it solves the problem. Why select this option? Your converting process needs to have a properly aligned web, there are no replacement parts for your current web guide, and you have the money to do it. Is it the fastest solution? Can’t really tell. We have heard of customers dealing with lead times that extend beyond 6 weeks, especially nowadays with the supply chain issues. What expenses should you consider? There is the cost of the new unit, the sourcing of new spare parts or consumables, adapting the unit to your converting line (yes, sometimes you will have to drill new holes in the machine or relocate rollers to adapt to the new configuration, it is not always a drop in), and the possible downtime or loss of efficiency while during the lead time. If you have several web guides in your converting line, and several converting lines in your operation, you will need to prepare to replace several units. 



## Replace components, web guide upgrade kits



Earlier in this article I indicated that most web guides fail in their controllers, sensors or actuators. The mechanical components can easily be replaced or fixed as they might involve replacing rollers, bearings or linkages. Sensors, controllers and actuators are specialty items designed and manufactured by the provider of the guiding system. As can be seen, spare parts are only sourced from the manufacturer.



Controllers, sensors and actuators can go obsolete with the fast pace changes in electronics. This poses a challenge for converters: are there spare parts for the current sensors, controllers or actuators that my webguide has? If not, can I adapt technology from another manufacturer. In the case of obsolete web guides, the answer has been no to both questions. However, there have been technological advances that have provided a solution to this problem in the form of upgrade kits.

 ![Old web guide system no longer operational - Upgrade](https://r2r.tech/sites/default/files/inline-images/Old%20North%20American%20Web%20Guide%20Upgrade.jpg)

[Upgrade kits](https://r2r.tech/products/web-guide-upgrade-kit?utm_source=blog032922) can provide sensors, controllers and actuators. The major technological break has been the ability to adapt sensors from one manufacturer into the platform of another manufacturer. Even though it does involve some labor installing an upgrade kit, it still gives substantial savings in getting an older system operational. One major advantage of upgrade kits is getting more advanced web detection capabilities into an older guiding system.



In our next post we will discuss upgrade kits for different types of web guiding systems.



If you have any questions regarding this and many other web guiding and monitoring problems or applications, [contact us](https://r2r.tech/contact?utm_source=blog032922) and we will help you in finding the best solution to your problem

---

# Pneumo-Hydraulic Web Guides Problems - What we know and what we can do for you

URL: https://r2r.tech/blog/pneumo-hydraulic-web-guides-problems-what-we-know-and-what-we-can-do-you.md

Many converting operations from the 60’s up to the 90’s adopted pneumo-hydraulic web guiding systems, especially in blown film lines, extrusion lines, flexographic printing presses and paper converting machines. These systems were a combination of a pneumatic sensor and  a hydraulic power unit and control to actuate a hydraulic cylinder to move the guide assembly. The control of this system is given by a servo valve that uses the signal from the pneumatic sensor to direct the fluid through two hydraulic lines to position the hydraulic cylinder at the desired location.



The advantages came from having more thrust from the hydraulic actuators, pneumatic sensors worked with opaque and clear homogeneous materials, where intrinsically safe due to the use of air, and were unaffected by dust accumulation.



However, **the disadvantages of using pneumo-hydraulic web guiding systems are numerous and can affect not only the efficiency of a converting line**, but can introduce contaminants to the web and safety issues within the production line. All these issues at the end are costly.

 ![Catching a hydraulic leak from a cylinder to protect the product in the converting line](https://r2r.tech/sites/default/files/inline-images/Cylinder-Leak-01_0.png) ![Power unit leak](https://r2r.tech/sites/default/files/inline-images/PowerUnitLeak-01_0.png)

We have run across quite a few of these units and have converted them to electromechanical web guiding systems with our **[upgrade kits](https://r2r.tech/products/web-guide-upgrade-kit?utm_source=blogdec152020)**.

 ![Upgrade Kit for Pneumo-Hydraulic Web Guides](https://r2r.tech/sites/default/files/inline-images/Retrofit%20Kit2%20%281%29.jpg)

Customers have approached us because they are having issues with hydraulic fluid leaks that are affecting the product or are causing safety issues for the operators in the converting line. Also, the cost of maintaining a hydraulic unit can increase with  time as the unit ages. Additionally, pneumatic sensors have issues of low resolution and inaccurate measurements.



So how can we help you if you are fed up with your aging pneumohydraulic web guide? We have a economical solution that not only eliminates these issues, but also allows you to use your web guide mechanism.



We have **[an article on our website](https://r2r.tech/articles/pneumo-hydraulic-web-guides?utm_source=blogdec152020)** with greater details on the issue of problems with pneumo-hydraulic web guide systems and our proposed solution. Don't wait any longer to get rid of the headache. And, by the way, we'll walk you through the entire process of upgrading your web guide and help you get more profits out of your converting line.

---

# Stepper vs Servo vs BLDC: Choosing the Right Motor for Web Guiding Actuators

URL: https://r2r.tech/blog/stepper-vs-servo-vs-bldc-web-guiding.md

*An engineer-to-engineer comparison of stepper, servo, and BLDC motor architectures for high-thrust web guiding actuators — when each makes sense, and where the tradeoffs lie.*

## Two Technologies, One Problem

When engineers spec high-thrust linear actuators for web guiding, the shortlist usually comes down to two motor technologies: stepper motors and brushless DC (BLDC) motors. Both can be paired with a ballscrew or roller screw to produce the linear forces web guiding demands. Both are mature, well-understood technologies with decades of industrial deployment behind them.

The choice between them is not about which motor is "better" in the abstract. It is about which motor architecture best fits the specific operating profile of web guiding — a profile that turns out to be unusual in ways that matter.

Before we get into our reasoning, it is worth establishing what that operating profile actually looks like, because it drives every conclusion that follows.

## The Web Guiding Operating Profile

Web guiding with a deadband has a distinctive duty cycle that sets it apart from most motion control applications:

- Corrections are brief. The actuator moves for fractions of a second at a time, typically at tens of millimeters per second.
- Corrections are infrequent relative to motor capability. A correction rate of 0.5 to 2 Hz means the motor spends the vast majority of its life at standstill, holding position.
- The position loop closes on the web, not the motor. A [Roll-2-Roll® Sensor](https://r2r.tech/products/sensors) measures the actual web position and commands corrections. Motor shaft position is an intermediate variable, not the controlled output.
- Thrust loads are high. Moving heavy guide frames, unwind stands, or rewinder carriages on linear bearings requires sustained force, primarily at low speed and at rest.

If you are designing for continuous high-speed rotation, high duty cycle, or applications where motor shaft position is the primary feedback variable, much of what follows will not apply to your problem. Those are applications where BLDC — particularly with field-oriented control — genuinely excels.

## What BLDC Actually Means — The Architecture Matters

"BLDC" covers two meaningfully different drive architectures, and the distinction affects every comparison point:

**Trapezoidal-commutated BLDC** is the classical form. The drive applies a six-step commutation sequence based on Hall effect sensor feedback. Current flows in two of three phases at a time. The result is approximately 13-15% peak-to-peak torque ripple at each commutation transition. This ripple is present at all speeds, including very low speeds.

**FOC (Field-Oriented Control) BLDC** applies continuously rotating current vectors using Park/Clarke transforms, producing smooth torque to zero speed. Modern FOC controller ICs are commodity components — capable silicon is available for under $5 in volume, and turnkey integrated drives are widely sourced. FOC has become the standard approach for any new BLDC design, and it would be misleading to compare stepper technology only against legacy trapezoidal drives.

We want to be clear: **FOC BLDC is excellent technology.** It resolves the torque ripple issues of trapezoidal commutation, provides smooth low-speed operation, and when properly commissioned, delivers servo-grade performance. The question is not whether FOC BLDC works well — it does — but whether the specific advantages it provides are the ones web guiding most needs.

## Low-Speed Smoothness: A More Honest Comparison

The original version of this comparison focused heavily on trapezoidal BLDC torque ripple. That was a fair point five or ten years ago but is increasingly less relevant as FOC drives have become commodity items. Let us compare against both.

**Against trapezoidal BLDC**, a stepper with 256-microstep interpolation does produce smoother low-speed motion. The sinusoidally-shaped current waveform from a modern intelligent microstepping driver subdivides each full step into fine increments, producing motion quality that genuinely exceeds six-step commutation at the low velocities web guiding demands. This remains a valid differentiator if you are evaluating a trapezoidal BLDC actuator.

**Against FOC BLDC**, the smoothness comparison is closer. A well-tuned FOC drive produces excellent low-speed torque quality — arguably better than microstepped stepper motion, particularly under varying load conditions. We will be honest about why: FOC continuously adapts its current vectors to maintain smooth torque production regardless of load, while microstepping accuracy degrades under load.

This is an important nuance. The 256-microstep resolution of a modern stepper driver implies very fine positioning increments, but under significant load the actual rotor position does not precisely track the electrical microstep position. The magnetic detent structure of the stepper means that under high thrust loads, the rotor "snaps" between positions that are coarser than the microstep count suggests. The motion is still smooth relative to full-stepping or half-stepping, and substantially smoother than trapezoidal BLDC, but it is not 256-counts-per-step precise under real load conditions.

In web guiding, this matters less than it might in other applications, because the outer web edge sensor loop is the true position authority. Microstep positioning errors at the motor are corrected by the next sensor reading. But we would rather you understand this limitation upfront than discover it on the bench and question everything else we have told you.

## Stepper Resonance: Real, and Manageable

Stepper motors have well-documented resonance issues in the 50-200 Hz range (corresponding to roughly 150-600 RPM for a 200-step motor). At these speeds, the interaction between the rotor inertia and the magnetic detent torque can produce oscillation, rough motion, and in severe cases, lost steps.

We will not claim this problem disappears. It does not. What we can say is that current-generation intelligent stepper drivers provide multiple features that specifically mitigate resonance in the web guiding operating regime:

- Voltage-mode PWM (silent operation mode) drives the motor with smooth voltage ramps rather than current chopping. This eliminates chopper noise and produces resonance-free motion at the low velocities where web guiding corrections occur. This is the primary operating mode for our actuators during correction moves.
- Cycle-by-cycle current control provides active damping during faster moves by continuously adjusting phase currents to suppress oscillation. When the actuator needs to traverse at higher speeds (e.g., during initial alignment or manual jog), this mode maintains stability through the resonant speed bands.
- 256-microstep interpolation subdivides step transitions into fine increments, reducing the energy impulse at each step boundary and lowering the excitation amplitude at resonant frequencies.
- Configurable acceleration ramps allow the motion profile to accelerate through resonant speed bands quickly, minimizing dwell time at problematic frequencies.

The deadband operating profile also helps — most correction moves occur at speeds well below the primary resonant band, and the move distances are short enough that the motor rarely accelerates into the resonant range at all.

The net result is that resonance, while physically present, is not a practical problem in our installed base of web guiding actuators. But it is an engineering reality of stepper technology that requires proper driver configuration to manage, and we think you should know that.

## Audible Noise: Steppers Are Louder

This is straightforward: stepper motors produce more audible noise than BLDC motors. The magnetic detent structure and the current switching patterns inherent in stepper operation generate acoustic noise that BLDC motors — which produce a smooth rotating magnetic field — largely avoid.

Voltage-mode PWM operation helps significantly. By replacing the high-frequency current chopping with smooth voltage drive, modern intelligent drivers reduce the characteristic stepper "singing" to a level that is unobtrusive in most industrial environments. In a converting plant with web transport machinery running, the actuator noise is not perceptible above ambient.

However, in quieter environments — a laboratory, a cleanroom, or a packaging line with minimal surrounding equipment — the difference is audible, and if noise is a critical specification, BLDC has a genuine advantage. We would rather tell you this now than have it become a surprise after installation.

## Sensorless Operation: A Genuine Simplification with a Real Limitation

A stepper motor self-commutates through its pole structure — it does not need any rotor position sensor to operate. This is an inherent architectural advantage over BLDC, which requires either Hall sensors (trapezoidal) or a high-resolution encoder (FOC) for commutation.

Modern intelligent stepper drivers add sensorless stall detection via back-EMF analysis, which monitors the motor's electrical signature to detect when the rotor has stopped following the commanded step sequence. This provides a safety net against mechanical obstructions or overload conditions without requiring any additional hardware.

For web guiding, sensorless operation eliminates sensor wiring inside the actuator, removes a failure mode (sensor failure or wiring damage), and simplifies field motor replacement — the new motor works as soon as it is wired for power. With hundreds of installed actuators across our customer base, the reliability benefit of fewer internal components has been validated in practice.

**The limitation we want to be honest about:** sensorless operation means there is no positive confirmation of move completion at the motor. The stepper driver knows what it commanded, and the stall detector knows if the motor stopped unexpectedly, but there is no direct measurement confirming the motor reached the intended position. The web edge sensor closes this gap — but with a transport delay of 0.5 to 2 seconds depending on sensor placement and web speed. For most web guiding applications, this delay is well within the control bandwidth and causes no issues.

For high-value webs where a single misguidance event during that transport delay could cause significant scrap or damage, an encoder option on the motor may be worth considering as additional insurance. We offer this as an option, and we think some applications justify it. The point is that the base architecture works without an encoder for the majority of installations, not that an encoder is never useful.

## Drive Complexity and Field Commissioning

This is where the stepper architecture provides what we consider its strongest practical advantage for OEM-supplied equipment.

A modern intelligent stepper driver requires configuration of: run current, hold current, microstep resolution, acceleration ramp parameters, and operating mode selection. These parameters are determined by the motor and mechanical load, set at the factory, and do not change at installation. There are no commutation parameters. There are no current loop gains that must be matched to motor electrical characteristics. There is no sensor calibration.

**FOC BLDC commissioning** is more involved. The drive must know the motor's electrical parameters (phase resistance, inductance, back-EMF constant) to tune the d-axis and q-axis current loops. Many modern FOC drives include auto-tuning routines that measure these parameters during an initial commissioning sequence — a genuine improvement over earlier generations that required manual tuning. The encoder must be aligned to the motor's electrical angle. Position and velocity loop gains may need adjustment depending on the mechanical load.

For a system where the OEM controls both the factory build and the field installation, FOC commissioning is entirely manageable. The auto-tuning capability of modern drives has substantially reduced the expertise required. We do not claim FOC is impractical — many thousands of FOC-based actuators ship successfully every year.

The difference is in the margin for error. A stepper system configured at the factory will behave identically in the field regardless of cable length variation, motor production batch variation, or the skill level of the installation technician. The parameter set is inherently robust because there are no closed-loop dynamics that can become unstable. For an OEM shipping actuators to diverse field environments with varying installation quality, this robustness is a meaningful advantage.

## Efficiency: Where BLDC Genuinely Wins (and Why It Matters Less Here)

The efficiency advantage of BLDC over steppers is real and undeniable. A BLDC motor draws current proportional to the torque being produced. A stepper motor draws significant current in both phases regardless of load — this is fundamental to how the detent holding mechanism works.

In a continuously-running, high-duty-cycle application, this translates to meaningfully lower heat generation and lower operating costs for BLDC. If you are building a high-duty-cycle actuator, BLDC efficiency is a compelling reason to choose it.

For web guiding with a deadband, the picture changes. The motor is at rest most of its operating life. Corrections are brief. Modern intelligent stepper drivers include automatic hold current reduction — stepping down to 30-50% of run current during standstill — which limits the efficiency penalty during the dominant operating state.

**Here is where we want to be honest about an argument that cuts both ways.** If the duty cycle is truly low enough that stepper efficiency losses are acceptable, it is also low enough that BLDC complexity costs (higher component cost, encoder requirement, commissioning burden) are spread over very little operating time. You are paying the complexity premium on a motor that is barely running. Both technologies can handle the thermal load of a low-duty-cycle application without difficulty. The question becomes which other factors — simplicity, cost, field serviceability — dominate the decision when efficiency is off the table for both.

## Power Density and Thermal Considerations

BLDC motors offer higher power density than steppers at equivalent frame sizes — more continuous torque per unit volume, primarily due to lower thermal losses from the efficiency advantage described above.

For web guiding with a deadband, the continuous torque rating is less relevant than the peak torque capability for brief correction moves and the holding force at standstill. Steppers produce their highest torque at low speeds and at standstill — a natural match for this profile. The duty cycle is low enough that thermal limits are not approached if the motor is correctly sized.

Our empirical validation: NEMA 34 frame stepper motors (approximately 7 Nm holding torque) reliably moving loads up to 20,000 lb on linear bearings in deadband-controlled web guiding, across hundreds of installations. Thermal limitation has not been a constraint in this operating mode.

## Cost Structure

Stepper motors and their drivers carry a lower bill-of-materials cost than equivalent-torque BLDC motors with FOC drives and encoders. NEMA-frame high-torque steppers are available from multiple manufacturers with stable pricing. Intelligent microstepping driver ICs are mature, high-volume silicon.

We will not make a broad supply chain argument here. Both stepper and BLDC components are available from multiple sources. Both have mature supply ecosystems. The cost difference is real but not dramatic enough to be the sole deciding factor — it is one input among several.

The more significant cost consideration for OEM actuator manufacturers is the total installed cost, which includes commissioning time, field service complexity, and spare parts inventory. A sensorless stepper system with no field tuning requirements has lower total installed cost than an encoder-equipped FOC system that requires commissioning — but the magnitude of that difference depends on your production volume, your field service infrastructure, and your customer base's technical capability.

## Where BLDC Is the Better Choice

We would lose credibility with you if we did not clearly state where BLDC — particularly with modern FOC drives — is the superior technology:

**High-speed continuous operation.** Stepper torque falls off sharply above the corner frequency (typically 500-800 RPM depending on supply voltage and motor inductance). BLDC maintains useful torque to much higher speeds. If your actuator needs sustained high-speed traversal, BLDC is the right motor.

**High duty cycle with thermal constraints.** In applications approaching continuous duty in confined enclosures, BLDC efficiency directly translates to lower operating temperature and longer life. The efficiency advantage that is academic at 5% duty cycle becomes decisive at 60%.

**Applications requiring precise shaft position feedback.** If your control architecture needs a motor-mounted encoder — because there is no external position sensor, or because you need move-complete confirmation with minimal latency — FOC BLDC already requires the encoder for commutation. Using it for position feedback adds zero incremental cost or complexity.

**Long stroke, high speed positioning.** Flying splices, rapid format changes, or any application combining high force with long high-speed strokes favors BLDC torque-speed characteristics.

**Noise-critical environments.** In laboratories, cleanrooms, or other quiet settings, BLDC produces meaningfully less acoustic noise than steppers even with voltage-mode PWM optimization.

These are genuine BLDC advantages, and if your application profile includes any of them as primary requirements, you should evaluate BLDC actuators seriously.

## Why We Chose Steppers for Web Guiding

Given all of the above — including the honest acknowledgment of stepper limitations — here is why we chose stepper motor architecture for our web guiding actuators:

**The operating profile is a narrow sweet spot for steppers.** Low speed, low duty cycle, high thrust at standstill, and position feedback from an external web sensor rather than a motor encoder. This specific combination of requirements aligns with stepper strengths and avoids stepper weaknesses. The overlap is not accidental — it is the reason we are a stepper-based actuator company for this application rather than a BLDC-based one.

**Sensorless architecture reduces installed complexity.** No encoder wiring inside the actuator, no Hall sensor connections, no commutation alignment. For an actuator that may be installed by a millwright rather than a motion control engineer, this simplification has practical value.

**No field commissioning eliminates a failure mode.** The actuator works the same way regardless of installation conditions. Our factory configuration is the field configuration. This matters when you have hundreds of units in the field across dozens of plants.

**Modern intelligent drivers have addressed the historical stepper weaknesses.** Resonance mitigation through voltage-mode PWM and active damping, automatic hold current reduction for thermal management, sensorless stall detection for safety — these features did not exist when the "steppers are primitive" reputation was established. They exist now, and they change the engineering tradeoff.

**The web sensor closes the loop where it matters.** This is the most important point. In a closed-loop web guiding system, the motor is not the position authority — the web edge sensor is. Microstepping positioning errors, open-loop position uncertainty, and any mid-correction disturbances are all captured and corrected by the outer sensor loop. This makes the stepper's open-loop nature a non-issue for the final system accuracy, while allowing the system to avoid the complexity of a motor-mounted position sensor.

## The Complete Comparison

| Factor | BLDC (Trapezoidal) | BLDC (FOC/Servo) | Stepper + Intelligent Driver |
| ------ | ------------------ | ---------------- | ---------------------------- |
| Low-speed torque smoothness | Poor (6-step ripple) | Excellent | Good (microstepping; degrades under load) |
| Sensor requirement | Hall sensors (required) | High-res encoder (required) | None required (encoder optional) |
| Resonance | Not applicable | Not applicable | Present (50-200 Hz); mitigated by driver features |
| Audible noise | Low | Low | Moderate (reduced by voltage-mode PWM) |
| Field tuning required | Commutation setup | Auto-tune + verification | No |
| OEM shipping suitability | Moderate | Good (with auto-tune) | Excellent |
| Efficiency at low duty cycle | Moderate advantage | Moderate advantage | Adequate (auto current reduction) |
| Cost (motor + drive + sensor) | Moderate | Moderate-High | Low |
| Drive complexity | Moderate | Moderate (modern drives) | Low |
| Thermal performance at high duty | Good | Good | Adequate (low-duty applications) |
| High-speed torque | Good | Excellent | Poor |
| Move-complete confirmation | Via Hall count | Via encoder | Via stall detect only (0.5-2s sensor delay) |
| Fit to web guiding profile | Marginal | Capable but overspec'd | Well-matched |

## Conclusion

We chose stepper motors for our web guiding actuators not because steppers are universally superior — they are not — but because the specific operating profile of deadband-controlled, sensor-corrected, high-thrust web guiding sits squarely in the stepper motor's best operating regime while requiring almost none of the capabilities that justify BLDC's additional complexity.

Modern FOC BLDC drives are excellent technology. If we were building high-duty-cycle actuators, high-speed positioning systems, or servo axes without an outer position sensor, we would likely be a BLDC company. Those are not the applications we serve.

The web edge sensor is the key architectural element that makes the stepper choice work. By closing the position loop at the web — where accuracy actually matters — the sensor makes the motor's open-loop positioning uncertainty irrelevant to system performance. The stepper provides the thrust, the sensor provides the accuracy, and the combination delivers reliable web guiding without the commissioning complexity of a closed-loop motor drive.

For high-thrust web guiding at low duty cycles, our experience across hundreds of installed actuators is that the stepper motor with a modern intelligent microstepping driver is the right engineering choice. Not because it is superior in every dimension, but because it is the simplest architecture that meets every requirement this specific application demands — and in engineering, that is usually the correct answer.

---

# The Declaration of Independence of the Thirteen United States of America, July 4th, 1776

URL: https://r2r.tech/blog/declaration-independence-thirteen-united-states-america-july-4th-1776.md

## Independence Day, July 4th



### May all Americans, current and aspiring, enjoy a happy Fourth of July!



![Declaration of Independence](https://r2r.tech/sites/default/files/inline-images/137334000012809056_zc_v2_declaration_of_independence.jpg)



> ### Read the complete Declaration of Independence!
>
>
>
> ### "When in the Course of human events, it becomes necessary for one people to dissolve the political bands which have connected them with another, and to assume among the powers of the earth, the separate and equal station to which the Laws of Nature and of Nature’s God entitle them, a decent respect to the opinions of mankind requires that they should declare the causes which impel them to the separation.
>
>
>
> ### We hold these truths to be self-evident, that all men are created equal, that they are endowed by their Creator with certain unalienable Rights, that among these are Life, Liberty and the pursuit of Happiness." 
>
>
>
> ### The Declaration of Independence of the Thirteen United States of America, July 4th, 1776
>
>
>
> ###  



##  

---

# The uncertainty of trade shows in 2021

URL: https://r2r.tech/blog/uncertainty-trade-shows-2021.md

# As you prepared the marketing budget for 2021, trade shows probably put a big question mark on your plan...



## We sat late last year discussing this particular item while preparing our 2021 budget.



Trade shows hit a huge speed bump with all the restrictions caused by Covid-19. We just didn't know if people were going to attend or if exhibitors would participate. In talking to partners and customers we found that this was a variable that was up in the air.



We have already heard from mayor exhibitors that have decide to skip trade shows in 2021 and focus on virtual presentations of their products and services. We have also heard from trade show organizers that are still working on preparing their shows and advertising their dates and venues. They are all in for in-person events. However, last years experience showed us that trade shows can shift quickly to virtual shows. Furthermore, dates have been changed to push shows further down the calendar year in hope of better Covid-19 numbers.

 ![Trade Shows](https://r2r.tech/sites/default/files/inline-images/LogosTradeShows.jpeg)

## 2020 brought the format of the virtual trade show.



Some were very successful, some had issues trying to figure out how to give their exhibitors and attendees an experience worth their time and money. Some exhibitors decided to create virtual venues within their companies and invite their customers and potential customers to visit with them in the virtual environment. One thing was certain, most major companies restricted the travel of their personnel to attend or participate in trade shows. Many restricted the visits to their facilities completely.



In the Converting industry some of the conferences and shows have announced their dates for 2021, such as Converters Expo South, Label Expo, World of Wipes, Converters Expo, Pack Expo, ICEC USA, among others. Yet some have held back such announcements to see if an in-person trade show is possible or if they should prepare a virtual event.

 ![Virtual Trade Show](https://r2r.tech/sites/default/files/inline-images/IMG_20200914_145400673_BURST000_COVER_TOP.jpg)

## Here's what we know.



The trade show industry is pushing for the in-person experience and is keeping in touch with marketing managers to offer the spaces available. Marketing managers would like to have these trade shows happen, their take is that it is still the best way to have a personal interaction with customers and a great launching platform for new products. However, exhibitors are still weighing in the pros and cons of showing up at these shows, considering that some of the major customers still have restrictions on travel for their personnel. The bottom line seems to be that companies who have their budgets committed to the shows will exhibit. Those that don't, will probably wait until next year. 



So far, trade shows have pushed their dates back in 2021, and some have already postponed farther into 2022. This is significant in the pulse of the industry, specially in relation to the converting sector. Just as exhibitors and attendees, trade show managers are hoping that the pandemic situation gets better. With this in mind, they will keep planning and scheduling shows betting on the chance that we will be able to attend these shows safely.  



Can shows continue being virtual? Yes, they can. But, they will have to up their game in what they offer the exhibitors and attendees. It's all about offering great content and experience, which will require investing in technology necessary for virtual expos. This will require greater knowledge of the virtual technology by the trade show industry. Can the exhibitors go on their own without trade shows? Yes, they can also. However, just as the trade show industry needs to improve on their offer with increased knowledge, so will the exhibitor that wants to do their own virtual experience for their customers.



One thing is certain, in-person trade shows will not have the big groups of people milling around booths, at least if they are following the recommendations of the CDC. Good thing is that it seems the a majority of the US population will be vaccinated by summer of 2021. 

---

# Vacuum web guiding

URL: https://r2r.tech/blog/vacuum-web-guiding.md

> Converting applications will typically require some type of guiding. It can be in the form of terminal or intermediate web guides, each with the peculiar conditions required to provide an effective placement of the web guide. However, all these applications are used in environments subject to atmospheric conditions. One of the most challenging web guiding applications deals with vacuum web guiding.



## Where is vacuum used in converting?



There is a process in converting called vacuum coating. This process applies a very thin and steady layer of coating to the surface of a film or substrate. The coating will protect the film as it is handled through other converting processes. These coatings will range in thicknesses from 0.25 to 10 microns. The coating can be achieved through Physical Vapor Deposition (PVD), Sputtering, Cathodic Arc, or Atomic Layer Deposition.



The use of roll to roll converting in vacuum deposition chambers allows for more material to be treated or converted instead of working on small individual pieces. The implication of this technique is the placement of the web guide inside the vacuum chamber. Mechanism, rollers, sensor and actuator have to fit inside this limited space volume with additional environmental conditions caused by the vacuum.



## What's different in vacuum web guiding?



For the purposes of web guiding, vacuum presents very interesting challenges due to environmental conditions and space limitations that come with vacuum coating. In vacuum you are faced with an environment with no air, no possible heat dissipation or outgassing. Vacuum can only be maintained in a special vessel. These types of vessels are expensive so you are faced with reduced volume or space. This also limits span lengths for web guiding and the number of rollers that can be used in the constricted space.

 ![Low Profile OPG](https://r2r.tech/sites/default/files/inline-images/WPS100.png)

## How sensors are affected



The lack of air or gas affects pneumatic, ultrasonic and infrared sensors in different ways. Pneumatic sensors need air flow from the emitter to the receiver to operate. Under vacuum, airflow is not possible. Ultrasonic sensors need air or gas for sound propagation. So, under a condition of vacuum sound propagation will not occur. Infrared sensors can work in vacuum as the infrared light can travel in vacuum. However, the fork style sensors are not capable of detecting transparent materials, such as clear films. This is due to the sensing principle of blocking.



A space devoid of gas or air also adds constraints such as heat dissipation and outgassing. Because there is no heat dissipation, then the heat generation from the sensor, and also the actuator, should be low. Additionally, the process of vacuum deposition requires that no other materials contact the surface of the film, so outgassing from sensors and actuators needs to be avoided completely. Outgassing will cause contamination of the deposition.



## Sensor space limitation



Fork style sensors occupy a good amount of space because of the two opposing arms. This limits how close the sensor can be placed to the exit of the web guide or in any space constricted space. As mentioned before, space is an expensive commodity in vacuum deposition converting.

 ![Fork Style Sensors](https://r2r.tech/sites/default/files/inline-images/Untitled%20presentation%20%284%29.jpg)

## A sensor that works in vacuum



Our sensors are light emitting sensors with single dimension cameras as receiver. However, the sensing principle is based on light scattering, not on blocking. Because of this principle, the [Roll-2-Roll Sensors](https://r2r.tech/products/roll-2-rollr-sensor)are capable of working with all materials, as all materials scatter light. Sensors based on the blocking principle have issues in detecting a transparent material, because transparent materials block very little if any light.



The design also allows for less space usage than the typical fork style sensor. With a low profile single sided design, our sensors fit in spaces where most sensors will not.

 ![Roll-2-Roll Technologies Sensors](https://r2r.tech/sites/default/files/inline-images/wps221family%20%281%29.jpg)

## We can help with your web guiding in vacuum application



Our sensor and web guiding technology provides you with a solution to guiding in vacuum conditions. We have provided some customers with our technology for their applications with successful results. If you are wondering about how to keep your web inline within a vacuum process you need to [contact us.](https://r2r.tech/contact)

---

# Web edge sensor for challenging web materials

URL: https://r2r.tech/blog/web-edge-sensor-challenging-web-materials.md

We are often asked by our customers to let them know if we can sense or edge guide a certain material. This is how this usually goes:



> We have a difficult to sense material. It is very porous, non-homogeneous, extremely translucent... Do you think your web edge sensor can see the material and guide the material?



And our answer typically is, yes we can.



### Seeing is Believing



Even though we believe we could see any material, we typically ask our customers to send a sample for testing. Seeing is believing, so we do some tests and send a video or a report to the customer. This gives them a sense of comfort and trust in our ability. We received one such sample from a customer oversees. The material was a nonwoven melt blown material. I wanted to share this because this is one of those challenging materials that are impossible to detect with typical web edge sensor. 



Here are some pictures send by the customer:

 ![Customer image of the material for web edge sensing](https://r2r.tech/sites/default/files/inline-images/web.jpeg)![Customer image of the material for web edge sensing](https://r2r.tech/sites/default/files/inline-images/web2.jpeg)

And here are the pictures from when we received the samples:

 ![Material that we received for testing our web edge sensor](https://r2r.tech/sites/default/files/inline-images/WebMaterial1.jpg)![Material that we received for testing our web edge sensor](https://r2r.tech/sites/default/files/inline-images/WebMaterial2.jpg)

Clearly the web is extremely porous with a lot of gaps. Any blocking/unblocking sensing principle would not be a good option. Let's see how our sensor performs.



### Roll-2-Roll® Sensor Performance



Well we will let the video speak for itself.

   

### What do you think?



Seeing is believing right! Our sensors are essentially a [line scan camera](https://r2r.tech/blog/line-scan-camera-vs-roll-2-roll-sensor) so they can overcome the limitations of conventional [web edge sensors](https://r2r.tech/blog/roll-2-rollr-sensor-just-sensor). We can indeed see any material, even without any setup or calibration. This video was taken with our standard factory default parameters. If you have some challenging materials that you are having trouble sensing, please give us a shout and we will help you guide it.



### Final Note



I want to leave you with a final note. Not everyone needs to guide such a material. Most often the customer get away without guiding the web and trimming off the edges to create a straight edge. But the problem with that is, every downstream process needs to trim certain amount and this can add up. If your machine accuracy, without guiding, is ± 0.25 in then you need to trim about 0.5 in of trim. If you can live with it then you don't need to guide the web. If not you do need guiding. Our guess is, more and more customers are looking for ways to reduce waste. If you are one of those customer please call us and we would be glad to help.

---

# Web guide and sensors, we are very good at what we do

URL: https://r2r.tech/blog/web-guide-and-sensors-we-are-very-good-what-we-do.md

## Converters, as many other industrial sectors, are always looking for solutions to their operational problems.  



### All we can say is that in web guiding and web monitoring systems, we are very good at what we do.



#### Reaching out to you



We are very good at contacting you when you reach out to us. Whether you [contact us for inquiries on our technology](https://r2r.tech/contact?utm_source=blog11242020) or a quote, we aim to respond to you promptly. We shoot for contacting you within the hour. We know when customers approach us they have a unique web guide or sensor problem. 



#### Customer engagement



We are very good at engaging the customer to understand their problem. We listen, carefully. We offer them our expert advice on possible solutions, even though it might turn out that the solution they need does not require our products or technology. In such a case, we provide them with guidance as to what they should be looking for. However, if we have a solution for them, we make sure they understand the application we are proposing. In some cases we are tasked with providing the least expensive solution. If it is a basic guiding or sensing operation we might not be the best answer to the customer. In any case, we always look at the whole picture. We want to make sure that we are not missing anything in our customers story that would affect the solution. We do shy away from using the term “cheap” in describing a solution. It’s a personal quirk. Cheap has a connotation of low quality more than low cost. So we use terms such as affordable, least expensive or inexpensive.



We know with the current pandemic, many of you cannot attend trade shows or even allow visits to your facilities. That is why we offer [live online demonstrations](https://r2r.tech/schedule-live-demo?utm_source=blog11242020)of our products and technology. All you need to do is schedule a time and date, and we will more than happy to show us the applications to solve your problem.



![Live online demos of web guide and web monitoring](https://r2r.tech/sites/default/files/inline-images/Live%20Demos%20R2R.jpg)



You also have access to our monthly webinars. We present to you varied topics, from the basics of web guiding to more advanced concepts and specific discussions of monitoring applications. Sign up by [contacting us.](https://r2r.tech/contact?utm_source=blog11242020) 



![Web Guide Fundamentals Webinar](https://r2r.tech/sites/default/files/inline-images/Web%20Guiding%20Fundamentals.jpg)



#### On-time delivery



We are very good at getting our web guides and web monitoring solutions to our customers on time. A typical lead time is 4 weeks. However, there are situations in which we present a longer lead of 6 weeks. Even then, we work hard at getting the product to you as soon as possible. If we consider we can deliver earlier than the quoted lead time, we notify you to make sure you are ready to receive the product. Most important, we rarely miss a shipping date.



#### Support



We are very good at helping our customers in the installation and operation of their systems. Our customers have access to a library of [manuals](https://r2r.tech/documentation?utm_source=blog11242020) and [instructional articles](https://r2r.tech/articles?utm_source=blog11242020) and [videos](https://r2r.tech/resources/videos?utm_source=blog11242020). We keep adding more content to our library. As we develop advances in our technology, we also create more support material. However, if you need to talk to us, we are always available to guide you.



#### Develop New Technology



We are very good at focusing our development on current and future problems that Converters face. You now have access to a sensor technology that is not affected by changes in material characteristics or environmental conditions. If you run only one material in your line, you probably might not need us. If you process varying density nonwovens on your line, you might want to get in touch with us to eliminate sensor calibrations. You need to eliminate physically repositioning the sensor or sensors to accommodate for running different web widths? We offer you a variety of sensor ranges, up to 35.5 inches, to eliminate sensor repositioning. You wanted to guide on the edge of a label to eliminate printing an additional line on your web for line guiding? [Our contrast sensor application was designed to provide multiple sensing options.](https://r2r.tech/videos/advanced-sensor-capabilities-converting-industry?utm_source=blog11242020) They can help guide a web based on a constant printed feature. Are you in need of monitoring multiple webs, such as strings or strips? Our technology allows us to count measure and monitor multiple webs 



![Thread Counting in Web Monitoring](https://r2r.tech/sites/default/files/inline-images/Thread%20COunting.jpg)



#### Our company is in the business of solving problems that others cannot solve or are less efficient at it than us.



We start by analyzing the problem with our customer.  until we are sure we understand the real issue. During this conversation we strive to educate our customer contact on the cause of the problem and the solutions available. In some cases, we have provided guidance to our customers about solutions that in a sense don’t involve our products. We can do this because our engineering staff not only has a clear understanding of web handling, but also has expertise in the development of the technology on which our products are based.



### What are we very good at?



Helping you solve your web guiding or web monitoring problem as fast as you need it, as simple as that.




  

---

# Web Guiding Applications and Advanced Web Guiding Concepts - Center Guiding

URL: https://r2r.tech/blog/web-guiding-applications-and-advanced-web-guiding-concepts-center-guiding.md

There are converting operations that require alignment of the web material to the centerline of the converting machine. In this case, you will usually find a two sensor setup for this type of guiding. This application is referred to as center guiding.



In our previous blog post we discussed the most basic of web guiding applications, one edge web guiding. In that case we were guiding to one of the edges of the web without regard to the other edge. ([Read more on single edge guiding in our previous blog](https://r2r.tech/blog/web-guiding-applications-and-advanced-web-guiding-concepts-single-edge-guiding?utm_source=011022blogpost)). The application uses a narrow sensing range sensor. It is the simplest solution for converting lines and it has its limitations and issues. In this post on center guiding, we will look at how center guiding works, its issues, and solutions with new technologies available.



# Center Guiding



Center guiding is used when the converting process requires that the web is maintained in the centerline of the converting machine. The control system will take the value from two sensors and use the average of the values to provide the centerline position. The center of the web is positioned to the center of the distance between the two sensors.

 ![Center Guiding with Two Narrow Range Sensors](https://r2r.tech/sites/default/files/inline-images/CenterGuiding-Two-Sensors-12in-01_0.png)

# Issues with Width Changes



When the converting line processes webs of different widths you need to reposition the sensors. This is due to the limited sensing range of the sensor. In this case the repositioning of the sensors is a little more complicated than the case of single edge guiding. Each sensor has to be moved half of the web width change from the center. Initially, this was done manually by operators or maintenance personnel by physically moving by hand the sensors from their position to a desired location. In operations where there are recurring widths, the operators mark the positions of the sensors for the different widths. In many cases these markings are made with rulers and markers, and are not very precise. As in the case of single edge sensing, the manual repositioning of web sensors introduces opportunities for operator error.



|  |  |
| --- | --- |



# Sensor Positioners



One way to eliminate operator error from manual repositioning of sensors is to use an electromechanical sensor positioner. Electromechanical sensor positioners can be actuated manually or automatically through the controls. The two sensors would be mounted on a lead screw, with an actuator that would actuate the lead screw to move the sensors in opposite direction away from or toward each other. Additionally, it would require a control with operator interface to instruct the actuator to move the sensors. In the manual operation of the controls, the operator repositions the sensors, but has to visually certify the correct position of the sensor. This process is time consuming, requires the proximity of the operator to the location of the sensors in the converting machine, and is still prone to operator error.



An automatic sensor positioning system would consist of the two sensors mounted on a lead screw, an actuator that would actuate the lead screw to move the sensors in opposite directions from or toward each other, and a control. The operator can instruct the system to move the sensors to positions already predetermined. The automatic system would also be capable of continuously adjusting the position of the sensors as the sensor positioner chases the web. In this case, the complete guiding system would have two control loops based on the feedback from the sensors, one would provide the position of the web web for the purpose of guiding it and the other would provide the repositioning adjustment of the sensors.



# Issues with Sensor Positioners



As any mechanical system, sensor positioners are subject to wear and tear. Their size occupies space that will restrict the location of the positioner on the converting machine. This location might not be the most efficient for guiding purposes.  What’s more, the actuator is in constant motion to adjust the position of the sensors. Operation of the system is complicated, it has two control loops and two control gains that must be taken care of, one for the guiding mechanism and another for the chasing mechanism of the sensor positioner. This requires an additional drive aside from the guiding system. All this makes this type of system expensive and in many cases bulky.



# Alternative Solutions



One recent solution that is becoming more popular is the use of [sensors with wider sensing](https://r2r.tech/sites/default/files/2021-11/ODC%20Product%20Brochure.pdf?utm_source=blog02012022) ranges. Converters can use two wider range sensors that can cover the web width change. In this case you eliminate mechanical moving parts, provide a simple installation and an overall lower cost of ownership.

 ![Center Guiding Two Wide Sensors - Narrow Web](https://r2r.tech/sites/default/files/inline-images/webWidthTwoSensorsWideSensors5in-01_2.png)![Center Guiding Two Wide Sensors ](https://r2r.tech/sites/default/files/inline-images/webWidthTwoSensorsWideSensors10in-01_0.png)![Center Guiding Single Sensor - Wide Web](https://r2r.tech/sites/default/files/inline-images/webWidthTwoSensorsWideSensors15in-01_1.png)


 For narrower webs there are sensors with a wide enough sensing range that [a single sensor can cover the entire web.](https://r2r.tech/products/odc-768?utm_source=blog02012022) The development of camera based sensors with a single face allows for better placement of the sensors. In comparison, fork style sensors that might have wide sensing ranges still occupy a considerable amount of space. This restricts the locations where these sensors can be placed.

 ![Center Guiding Single Sensor - Narrow Web](https://r2r.tech/sites/default/files/inline-images/5webWidthSingleSensor5in-01_1.png)![Center Guiding Single Sensor](https://r2r.tech/sites/default/files/inline-images/webWidthSingleSensor10in-01_0.png)![Center Guiding Single Sensor - Wide Web](https://r2r.tech/sites/default/files/inline-images/webWidthSingleSensor_0.png)


 Like our technical and application blogs on web guiding and web monitoring? [Sign up to receive our monthly newsletter](https://r2r.tech/contact?utm_source=blog02012022). If you have a pressing issue in your converting line, make sure to tell us about it and we will do our best to helpThe use of wider range sensors and the most recent wide range camera based linear sensors are not limited to guiding. There are applications in web monitoring, such as width measurement. These will be discussed further in other blogs in the near future. Our next blog in this series regarding applications and advanced web guiding concepts will address guide points. 

---

# Web Guiding Applications and Advanced Web Guiding Concepts - Single Edge Guiding

URL: https://r2r.tech/blog/web-guiding-applications-and-advanced-web-guiding-concepts-single-edge-guiding.md

In 2020 we hosted a webinar on web guiding applications and advanced web guiding concepts as a continuation of the educational series web guiding fundamentals. This webinar was the follow up on our seminar on [Web Guiding Fundamentals](https://www.youtube.com/watch?v=3PQts0pmKP0?utm_source=blog01052022), presented earlier that year, and commented in a series of blog posts in 2021. We would like to share some comments on the points presented in this webinar in the form of a series of blogs. Hopefully, this will serve as an aid to personnel in the converting industry that are just beginning to deal with web guiding and other related applications.



## Edge Guiding - Single Edge



Single edge guiding is the most common guiding application available. In this case, a guiding system employs one sensor located at one of the edges of the web. The sensor will be mounted on either the operator side or the drive (gear) side. It is important that the fundamentals of web guiding are followed in [the installation of the sensor](https://r2r.tech/blog/web-guiding-fundamentals-web-guiding-performance?utm_source=blog01052022) in order for it to perform efficiently. The web is guided to the center or middle of the sensor, so the sensor should be positioned to provide enough feedback on the current position of the web to allow for corrections of the web opposition by the web guiding system.



## Issues with Single Edge Guiding



Edge guiding applications will work well for most cases. However, it will have issues when the application is faced with web width changes. The sensor might have to be repositioned depending on the [sensor range](https://r2r.tech/blog/web-guiding-fundamentals-sensors?utm_source=blog01052022) and the amount of change on the width of the web. As the web changes width and the sensor is repositioned, we are faced with a change in distance from the face of the sensor to the plane of the web.



|  |  |  |
| --- | --- | --- |



This can cause problems if the web width change is significant as the distance between the sensor face and the web will vary greatly from the narrowest of widths to the widest.



Bear in mind that physical repositioning of the sensor can result in operator error, especially in locating the sensor relative to the machine, or locking it in position. Those are just a couple of situations that can happen. There certainly are more.



There is also the condition in certain converting operations where the web position is not in the center of the machine. In this case, the web is aligned to either the operator side or the drive side:



![](https://lh6.googleusercontent.com/5ip5pZK1rgjEj-d5Z2OLhVffn0tpJLxJ8f-oi10MyzhEm5F57X_RihLzPWd1wWwQo3_jbwVODbHclBWTBjoACxvFfOrmW6C1ol5-92ityOnEzxXbek8zS-DHaQcIKoqAiyOR_l-t)



If the alignment of the web is constant on one edge, that is, the edge is fixed in relation to the machine, then you avoid having to reposition the sensor. If it is not, then you will have to deal with sensor repositioning.



We hope this information is of benefit to you and your personnel. [We have more articles and videos with information and you can keep up to date on our latest developments and educational materials by signing up for our newsletter](https://r2r.tech/contact?utm_source=01052022blog). Questions about web guiding and monitoring or web handling in general? [Feel free to contact us](https://r2r.tech/contact?utm_source=01052022blog), we will be happy to help you out with your inquiry.



In our next blog post we will discuss center guiding as a web guiding application. Be on the lookout for this post and other posts that will follow.

---

# Web Guiding Fundamentals - A Summary

URL: https://r2r.tech/blog/web-guiding-fundamentals-summary.md

> ## Web guiding is that component of a converting line that no one thinks about until it affects the converting operation.



In some cases, we believe that a problem in a converting line is due to guiding issues when it really isn't. That is why it is important to understand web guiding, and why we invest time in creating this series in web guiding fundamentals. First, the best way to prevent issues with web guiding is to understand how it works, how to best select and install a system, and what we should consider when trouble shooting. We want to take web guiding from an obscure part of the converting process into a feature that operators, technicians and process managers feel comfortable with.



This blog post on web guiding fundamentals is that last blog on this series. It is not the last blog post on web guiding and web detection and monitoring as we will continue to post pieces that will be valuable in understanding this area of web handling. [You can always contact us](https://r2r.tech/contact?utm_source=blog07012021) if you have a particular web handling concern that in which you require some help.



So, here is a summary of the web guiding fundamental posts during these past few weeks:



- There is no perfect system in converting. That is why web guiding is necessary. Webs, machines and processes are not perfect, therefore, expect the web to divert from the ideal location at any moment.



- The normal entry rule applies to any converting process that has webs going through rollers. Any deviation in the roller alignment will make the web move. Remember, webs seek to align perpendicular to the roller axis.



- Web guiding systems require the feedback from the web edge or contrast sensor. A sensor that is several spans away from the exit roller of a web guide is worthless. So, you need to place the sensor as close as possible to the exit roller on the exit span of the web guiding system.



- The same goes to web guide location on the converting process. The web guide needs to be as close as possible to the critical process in the converting line that requires an aligned web.



- Loss of traction, also interpreted as loss of tension, will result in poor guiding performance. The reason, low traction will cause the web to slip over the roller face on the web guiding system



- Proper installation of web guides will lead to good guiding performance. In general, install the web guide as close as possible to the critical process where the web needs to be aligned, have the sensor located in the exiting span as close as possible to the exit roller of the web guide, make sure the entry and exit spans have the proper distance based on the width of the web.

 ![OPG installation mistakes](https://r2r.tech/sites/default/files/inline-images/offset_pivot_guide_installation_mistakes%20%281%29.png)

- Improper installation can result in edge stresses and web instability



- Guiding performance depends on sensor, actuator and controller capability



We hope his information helps you with better understanding of web guiding. We will soon start the series on advanced web guiding applications and concepts.

---

# Web Guiding Fundamentals - Common Terminology

URL: https://r2r.tech/blog/web-guiding-fundamentals-common-terminology.md

As a converter that deals with the day to day operation of a converting line you probably run into issues with communication within your operation, or externally with suppliers. Your problem is how do you efficiently get your point across? It definitely helps if you use the proper terminology or understand other terms used in the industry. We want to help you with that with our Web Guiding Fundamentals series.



## A web guide is a web guide is a web guide by many different terms.



A little poetic here, but in general terms a thing is what it is (not truly the interpretation of Gertrude Stein, the poet who wrote “a rose is a rose is a rose” in one of her poems, but we will use it here in this context). As you talk to different people in the industry, you will find a variety of terms to identify a web guide. Here we will give you a short presentation of terms and definitions of web guides to get you started in the trek of web guiding fundamentals.



![Web Guiding](https://r2r.tech/sites/default/files/inline-images/90%20degree%20wrap-01_0.png)



## Steering and Tracking 



These two common terms are widely used to identify a web guide. Steering is based on the premise that the mechanism moves or steers the web to its correct position based on the current position detected by the guiding system. Tracking is based on the premise that the web is detected and followed as the mechanism makes the appropriate corrections to place it in the correct position. Two denominations, same thing.



## Edge, Line and Contrast Guiding



In this case the web guide is defined or identified based on the feature of the web that is used to track its position. Guiding is done in reference to the position of the edge of the web, the location of a printed line or a visible contrast on the web surface. 



## Lateral Control and Lateral Registration



These are academic terms to identify a web guiding system. Why would you need to know this? Well, many of the advances in web guiding technology are achieved under academic research. If you attend a technical conference on web handling or just happen to run into an academic paper on the subject, you will definitely see such terminology. Wouldn’t it be nice to know as you look through a conference agenda that there is a presentation on Lateral Control and Lateral Registration and you are interested in what’s going on in new developments in web guiding?  



## CD Registration and Lateral Alignment 



You will occasionally run into these two terms in web guiding. Cross-Machine Direction Registration and Lateral Alignment are also used in academic research, but it does cross-over into converting operations, especially in very large companies that have research facilities. In both cases, the reference is the alignment of the web in lateral form with respect to the direction of travel of the web material through the converting equipment.



## EPC and LPC 



These two terms (EPC - Edge Position Control and LPC - Line Position Control) are commonly used in Asia. One refers to  edge guiding and the other to line and contrast guiding.



There are a good variety of terms to identify web guides. However, there is additional terminology based on the actuating system, web guiding mechanism and position of rollers. You can read more on this in our [Web Guide Selection and Installation Tips.](https://r2r.tech/articles/web-guides-selection-and-installation-tips?utm_source=blogMarch16)



On a final note, web guides position the web laterally or in desired cross-machine direction to enable efficient transport. If a web is not guided we will have issues of the web crashing into the machine. We will continue presenting more information on Web Guiding Fundamentals in future posts. [Contact us](https://r2r.tech/contact?utm_source=blogmarch16) to continue receiving information on web guiding and web sensor applications or if you have any specific questions regarding web guiding or sensors for web detection and monitoring. We look forward to helping you succeed with your converting operation.

---

# Web Guiding Fundamentals - Displacement web guide considerations

URL: https://r2r.tech/blog/web-guiding-fundamentals-displacement-web-guide-considerations.md

## Displacement Web Guide - The most commonly used



> Within the group of intermediate web guides, we find the displacement web guide or off-set pivot web guide. For any web guiding application we would recommend this type of web guide as a first choice. One of the main reasons for this recommendation is this type of web guide actually displaces the web without bending the web.



The reason it does not bend the web is that the web guide has an entry span, a span between the rollers on the pivot carrier or pivoting table, and an exit span, where the web is wrapped around all the rollers at a 90 degree angle. The table pivots around a point that is at the back edge of the entry roller on the carrier or pivot table. The two rollers on the table move in tandem, so there is no bending of the web in the region or span between the pivoting table rollers. In the entry and exit spans, the motion of the web with respect to the rollers is perpendicular, so the motion on the web is a twisting motion. This is the reason we call these the perfect web guide.



If the web guide is designed properly, it will have a one-to-one ratio; if you move the web guide one unit, the web will move one unit. Because there is no bending on the web, displacement web guides do not use the principle of normal entry for displacement of the web. The rollers on the table are parallel to each other, and the rollers that create the entry and exit span are perpendicular to the web, then there is no resulting bending of the web, and therefore, less stresses. 



## Installation

 ![Displacement Web Guide](https://r2r.tech/sites/default/files/inline-images/Displacement%20Web%20Guide%20Schematic.jpg)

### The 90o wrap



The proper installation of a displacement web guide requires a 90o degree wrap of the web around the rollers that create the entry and exit span and the rollers on the pivot table. However, a slight deviation of +/- 5o is acceptable.



### Entry and exit spans



Regarding the length of the entry and exit spans, these should be at least 0.5 x the web width, with a recommended 1 to 2 web widths if it is possible. For stiffer webs such as metals longer spans, 3 x and above the web width, is recommended.



### Sensor position



The sensor should be located as close as possible to the roller on the pivoting table in the exit span. This holds for all types of web guides, the sensor position is best when it is close to where the guiding action occurs. A general rule of thumb is to make sure the sensor is located within the first half of the exit span.



### Guide span



The guide span is the distance between the centerline of the rollers on the pivoting table. This span is determined by how much correction is required. Typically, the pivoting tables will be allowed to pivot 5o to 10o. If you require greater correction you can design the pivoting table with a longer span. Guide spans can also be restricted on space available within the converting machine where the web guide will be installed.



You want to keep in mind that the plane of motion of the pivoting table is perpendicular to the entry and exit spans to guarantee a pure twist on the web at the entry and exit spans. As long as the rollers on the pivoting table are parallel to each other you will have the desired guiding effect.



The rollers on the guide span do not need to be on the same carriage or pivoting table. As long as they maintain the parallelism during the guiding motion, they will provide the web guiding required. You can even have a process occurring between the two rollers on the guide span, or even have multiple rollers within the guide span. In general, the guiding action occurs at the exit span.



### Displacement guide no-no: What not to do.



#### Sensor installed too far away or in the wrong span

 ![Sensor Position No-No](https://r2r.tech/sites/default/files/inline-images/Sensor%20position%20no-no_0.jpg)

You don't want to install the sensor too far down the exit span, on the span following the exit span, or on any other span for that matter. In this case, when the web guide makes a corrective action that action will not be seen at the sensor immediately. In systems where the web is running at high speeds, you might get away with placing the sensor further down the exit span. However, on slower operations or when the web stops placing the sensor lower down the exit span or in the next span will lead to the web guide continuing its corrective action when it is not necessary. The result could be a damaged web.



#### Wrap angle less than 90o



![Wrap angle less than 90 deg. on exit and entry span](https://r2r.tech/sites/default/files/inline-images/Wrap%20angle%20less%20than%2090%20deg%20at%20entry%20and%20exit%20span_1.jpg)



When the wrap angle at the entry span, exit span or both are below 90o beyond the +/- 5o tolerance you will introduce bending on the web with resulting understeering of the web. Additional effects would be increased distortion of the web, bending of the web in the span with the reduced wrap angle and guide instability.



![Wrap angle less than 90 on entry span](https://r2r.tech/sites/default/files/inline-images/Wrap%20angle%20less%20than%2090%20on%20entry%20span.jpg)



![Wrap angle less than 90 on exit span](https://r2r.tech/sites/default/files/inline-images/Wrap%20angle%20less%20than%2090%20deg%20on%20exit%20span.jpg)



#### Wrap angle greater than 90o



![Wrap angle greater than 90 deg.](https://r2r.tech/sites/default/files/inline-images/Wrap%20angle%20greater%20than%2090%20deg.jpg)



When the wrap angle is greater than 90o there will be over-steering of the web due to the bending effect on the web. As with the previous case, deviations from the 90o wrap around the entry or exit roller of the web guide will also increase distortions on the web and high edge stresses.



#### Displacement guide wrap options



Another design and installation issue with displacement web guides is the web path through the web guide rollers or guide wrap. There are four basic options that would allow us to orient the entry and exit path of the web through the guide:

 ![Inverted U-Path](https://r2r.tech/sites/default/files/inline-images/Inverted%20U-Path.jpg)

Configuration A shows an inverted U-Path of the web on the web guide. This is probably the most commonly used web path in the converting industry

 ![Configuration B](https://r2r.tech/sites/default/files/inline-images/Z-Path%20B_0.jpg)

Configuration B presents a Z-Path for the web on the web guide system. The entry of the web into the web guide is from the top and exits down. This is an option where the web at the exit needs to remain in the same orientation as in the entry. It requires idler rollers on the entry and the exit to create the entry and exit spans.



|  |  |
| --- | --- |



Configuration C is a similar Z-Path as in configuration B. However the direction of travel of the web has an entry from below and exit to an above span. Configuration D is an U-Path. This configuration is appropriate when the web guide is low on the converting machine and there is no room for idler rollers below the web guide to create the entry and exit spans.



Now, these four basic configurations lead to 16 different configurations just by placing the web guides in different orientations. Of importance is that the entry and exit spans are perpendicular to the guiding plane of the web guide.



### Displacement Guide - Summary



#### Design considerations



The main displacement guide design consideration is the desired correction. As mentioned before, the desired correction will determine the guide span, the distance between the rollers on the guiding carrier. 



#### Installation considerations



When dealing with installation considerations, space available, web stiffness, wrap angle at entry and exit and wrap options based on web path are the main considerations. Displacement web guides have the advantage that they can be placed close to the critical process in the converting line. However, the location of the web guide will be dictated by the amount of space available in the process. Web stiffness will affect the entry and exit spans. Stiffer webs will require longer entry and exit spans.



The location of the web guide must also consider the need to maintain the 90o wrap angle around the guide rollers for all the reasons mentioned before regarding the effects of an inadequate wrap angle. Finally, the wrap options for the path of the web through the web guide are determined by the web path through the converting machine. 



#### Advantages of displacement guides



Displacement guides are very simple to install. Typically, the web guide mechanism will be supplied to the customer ready to install in the machine. Of course, this is highly dependent on how well your web guide supplier worked with you in the design and installation considerations early in the selection process. So, this point of providing the information of your web material, speed, tension, correction desired and space restrictions will payoff greatly when the web guide is installed and placed in operation.



Displacement web guides also place the least amount of stress on the web when dealing with intermediate web guides. However, in order to do this the web guide must be properly installed.



Best of all, these types of guides allow the designer and user a variety of installation options based on the different web paths that can be used.



#### Disadvantages



The maximum correction cannot be more than the guide displacement. More than a disadvantage it is a limitation.



So far, we have discussed two types of web guides, [terminal web guides](https://r2r.tech/products/roll-2-roll-unwindrewind-guide?utm_source=blog05182021) and [displacement guides](https://r2r.tech/products/displacement-guides?utm_source=blog05182021) in the group of intermediate web guides. Our next blog will discuss the [Steering Guide](https://r2r.tech/products/web-guides/steering-guide)(https://r2r.tech/products-groups/steering-guides?utm_source=), another web guiding system in the intermediate web guide group. The best practice when selecting a web guide system is to discuss with your wbe guide supplier your needs and conditions. This will guarantee a proper selection of a web guide solution for your operation.



If you are interested in this and other topics related to web guiding and web monitoring, [sign up for our monthly enews letter](https://r2r.tech/contact?utm_source=blog05182021). There you will be informed of new solutions and applications and of webinars held throughout the year. 

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# Web Guiding Fundamentals - End and Center Pivot Guides

URL: https://r2r.tech/blog/web-guiding-fundamentals-end-and-center-pivot-guides.md

## End and Center Pivot Guides - Not a commonly used web guide in the industry



> End and center pivot guides do not displace the web, they only have the angle of rotation to reposition the web. This makes them very slow in term of response, and therefore, are not an ideal choice in web guiding options.



[Terminal web guides](https://r2r.tech/products/roll-2-roll-unwindrewind-guide?utm_source=blog06012021) such as unwind and rewind guides and intermediate guides such as [displacement guides](https://r2r.tech/products/displacement-guides?utm_source=blog06012021) and [Steering Guides](https://r2r.tech/products/web-guides/steering-guide)(https://r2r.tech/products-groups/steering-guides?utm_source=blog06012021) are the most commonly used web guides in the converting industry.



Unwind guides are used at the start of a converting line, and the roll is mounted on a carriage or side-lay that will move to correct the position of the web based on the detected edge of the web.



Rewinds web guides, as we have seen in previous posts, have the roll mounted on a carriage or side-lay, but it actually repositions the carriage as it chases the position of the web.



Displacement guides are the best type of web guiding system as it eliminates any bending stresses on the web, if the guide is designed and installed correctly. Steering guide are best when the web is coming out of a very long span, for example, at the exit of an oven. 



However, there is a lesser known web guide design that is not very efficient and is not usually found in new converting operations. These are end and center pivoted web guides.



## How end and center pivot guides work



End and center pivoted web guides work by using the normal entry rule to guide or steer the web. By using the normal entry rule, these web guides subject the web to bending and therefore, stresses on the web.



As with other intermediate web guides, they follow the same requirements in parameters of the pre-entering span, entering span and exiting span. Pre-entering span should be shorter than the entering span, the sensor should be as close as possible to the guide roller on the exiting span, the exiting span should be perpendicular to the exiting span, and wraps angles around the rollers should be close to 90o.

 ![End and Pivot Web Diagram](https://r2r.tech/sites/default/files/inline-images/End%20and%20Center%20Pivot%20Web%20Guide%20Diagrams.jpg)

As in other types of guides, poor installation will cause wrinkles, creasing and possible web tear depending on web material and thickness.



### End Pivot Guides



End pivot guides will have the axis of rotation at the end of the guide roller shaft. Both ends of the roller will have the same amount of angular displacement, but the end of the roller farthest from the pivot point will have the most amount of arc length. The end of the roller closest to the pivot point will have less arc length.

 ![End Pivot Web Guide](https://r2r.tech/sites/default/files/inline-images/Pivot%20Web%20Guide.jpg)

This action changes the plane of motion of the guide roller. The web will adjust its position as dictated by the normal entry rule. 



### Center Pivot Guide



Center pivoted web guides have the angle of rotation at the middle of the guide roller. Unlike the end pivoted web guide, the angular displacement is the same at both ends of the guide roller. Both ends of the guide roller will have the same arc displacement, in directions opposite to each other.

 ![Center Pivot Web Guide](https://r2r.tech/sites/default/files/inline-images/Center%20Pivot%20Web%20Guide.jpg)

The rotation of the guide roller at the middle of the guide roller length changes the plane of motion of the guide roller. Like the end pivoted web guides, this change in plane of motion will cause the web to adjust its position until it is perpendicular to the roller axis, as the normal entry rule dictates.



## Use of end and center pivoted web guides



As mentioned before, the use of end and center pivoted web guides is not recommended for converting operations. However, these can be found in machines processing narrow webs with rollers and equipment with cantilever installation, and lines that have very limited spaces.



We do have displacement guides for very narrow width applications. These web guides allow converters to place a web guide in small spaces to handle narrow webs under 2 inches.

 ![Micro Displacement Guides - A solution for end and center pivot guides](https://r2r.tech/sites/default/files/inline-images/Micro%20Web%20Guide.jpg)

## You have a end or center pivot web guide: what can you do?



[Start off by getting in touch with us](https://r2r.tech/contact?utm_source=blog06012021) so we can guide you to a solution of your particular issue. Our technical team would be there for you through every single step of the process until a solution is found.



In our next blog post we will address an important component of a web guiding system: actuators. 



If you like our posts, follow us on [linkedin](https://www.linkedin.com/company/roll-2-roll-technologies-llc), [facebook](https://www.facebook.com/roll2rolltechnologies), or [youtube](https://www.youtube.com/r2r-tech). You can always [contact us](https://r2r.tech/contact?utm_source=blog06012021) directly to discuss a particular application for your operation.

---

# Web Guiding Fundamentals - Intermediate Web Guides

URL: https://r2r.tech/blog/web-guiding-fundamentals-intermediate-web-guides.md

# Intermediate Web Guides



## Used before a critical process in the converting line 



In our previous post on web guiding fundamentals, we mentioned the [terminal web guides.](https://r2r.tech/products/roll-2-roll-unwindrewind-guide?utm_source=blog04062021) These are web guides that are found at the start or the end of the process. Their location is usually on an unwind or a rewind stand. As we discussed, their installation depends on whether the guiding system is used for unwinding a roll of web or rewind a processed web into a roll.



|  |  |
| --- | --- |



## Web Guiding within the converting process



Intermediate web guides are located before any critical process in the converting line. We know that machines and materials are not perfect. In order to assure that the web is correctly aligned to a printing station or slitting operation, we require to correctly align the web at a point as close as possible to where the critical process will occur. 



## There are several different types of intermediate web guides.



The most commonly found web guide type in the industry is the [Off-set Pivot Guide (OPG)](https://r2r.tech/products/displacement-guides?utm_source=blog04062021). These guides are also referred to as:



- Displacement Guides
- Positive Displacement Guides
- Pivot Frame
- Table Guide

 ![Wide Web Guide System](https://r2r.tech/sites/default/files/inline-images/WideWebGuide.jpeg)![Low Profile OPG](https://r2r.tech/sites/default/files/inline-images/LowProfileGuide.jpeg)

The second most common web guide type found in the industry is the [Remotely Pivoted Guide](https://r2r.tech/products-groups/steering-guides?utm_source=blog04062021), also known as:



- Steering Guide
- Steering Roll
- Swivel Roll



However, there are other less common intermediate guides that converters must consider when selecting a system for their converting line, such as end pivoted guides, center pivoted guides and turn-bars.



In future blogs we will go into more detail on web guiding systems and the dynamics, including the main principle behind web guiding that allows converters to correct the position of webs.



We invite you to [sign up to receive information](https://r2r.tech/contact?utm_source=blog04062021) on web guiding and web monitoring. There are many exciting developments that will come up this year that your operation will benefit from.



                                                                                                                                                                                                                                                                                                                  

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# Web Guiding Fundamentals - Main Components of a Web Guiding System

URL: https://r2r.tech/blog/web-guiding-fundamentals-main-components-web-guiding-system.md

### A web guiding system for converting operations has four main components:  



- Guide Structure/Mechanism
- Actuator
- Sensor
- Controller



However, even though we mention four main components, the web has to be considered a component of the web guiding system.



### The guide structure is the device that makes contact with the web...



and therefore, needs to be moved to reposition the web to a correct location. There are many different types of guide structures that we will address in our next posting in Web Guiding Fundamentals. 



![Low Profile OPG mechanism](https://r2r.tech/sites/default/files/inline-images/Low%20profile%20web%20guide%20with%20the%20manual%20sensor%20adjustment-01.png)



### The actuator takes an electrical signal...



and converts it into physical motion used to move the guide structure lo position the web in the desired position.

 ![Electromechanical Actuators](https://r2r.tech/sites/default/files/inline-images/final1070_0.jpg)

### The sensor provides the feedback.



It tells us where the web is, inferring its position. The signal is then sent to the controller.



![Line of Sensors Roll-2-Roll Technologies](https://r2r.tech/sites/default/files/inline-images/SensorFamily05option.jpg)



### The controller is the intelligence of the web guiding system.



It takes the sensor signal and computes the corrective action required so the actuator moves the guide mechanism to a location that would place the web in the desired position.



![Controller with sensot](https://r2r.tech/sites/default/files/inline-images/Controler_burlapWeb.jpg)



### A web guide system schematic  

 ![Basic Components of a Web Guide](https://r2r.tech/sites/default/files/inline-images/Components%20of%20Web%20Guide.png)

This particular schematic represents an off-set pivot guide. The web guide mechanism would contain the rollers and table, the actuator and in the case of a compact off-set pivot guide, the controller and operator interface. In the schematic you see the sensor and the web. As mentioned before, the web has to be considered as part of the web guide system.



The sensor gets the position feedback of the web and sends the information to the controller. The controller computes an error and sends the command to the actuator so the mechanism can be moved to place the web in the desired location. This is a closed loop feed back control system.



### Web guide structures



There are several types of web guide structures, such as [terminal guides](https://r2r.tech/products/roll-2-roll-unwindrewind-guide?utm_source=blog04132021) (unwind and rewind guide structures), and [intermediate web guides](https://r2r.tech/products/web-guides?utm_source=04132021). These we will address in future blogs regarding Web Guiding Fundamentals.



Join the learning community!



Keep up with the latest information on Web Guiding Fundamentals and other subjects by [signing up one our website for the blog other informational emails.](https://r2r.tech/contact)

---

# Web Guiding Fundamentals - Normal Entry Rule

URL: https://r2r.tech/blog/web-guiding-fundamentals-normal-entry-rule.md

## Most web guides work on the fundamental principle of Normal Entry.



This rule states that a web approaching a roller will align itself perpendicular to the axis of rotation of the roller. The Normal Entry principle accounts for one of the most common defects in a converting line, roller misalignment. If your converting line has one roller that is not correctly aligned perpendicularly to the required path of the web, the web will move in order to be perpendicular to the misaligned roller. After that position, the web will then be at a location that is probably not the desired location. It will require correction by an alignment system.



## Web guides are based on the effects of roller misalignment



In a sense, roller misalignment is used to correct Web guides that align the material using the same normal entry principle. By deliberately changing the axis of rotation of the guide roller, the web guides steer to a different position. Several types of web guides are used to align the web; the difference is in the way the axis of rotation of the roller is changed.



## The web is like a beam.



When the web is subject to a change in the axis of rotation of the roller, the web behaves like a beam. The angular displacement of the roller axis bends the beam, and this bending force causes the web to move on the roll until it is perpendicular to the axis of rotation of the roller. Jerry Brown created a video that represents very well this principle:





However, there are dynamic factors that will affect how the web moves such as speed of the web, tension, web material and friction between the surface of the web and the roller in order for the normal entry principle to have an effect. For example, if the web is able to slip on the surface of the rollers, the web would completely slip off both rollers as it tries to achieve a perpendicular position to the misaligned roller axis of rotation. As you could see in the previous video, the web moved up on the misaligned roller until it achieved its final position perpendicular to the axis of rotation of the displaced roller. At this steady state you notice that the web remained in position in the fixed roller upstream as it has enough traction to avoid any movement on the surface of the roller. The web is subject to bending, and as a beam, it is subject to stresses due to the bending. You will have a tight side and a slack side and there will be a tension profile through the web due to the bending of the beam or web.

 ![Animation showing the working of a guide mechanism.](https://r2r.tech/sites/default/files/inline-images/Guiding-Top-View.gif)

Many intermediate web guides depend on this principle to properly align the web with the process. So, it is important to understand this principle to help you understand how a web guide works.



In future blogs we will go into more detail on web guiding systems and the dynamics.



We invite you to [sign up to receive information](https://r2r.tech/contact?utm_source=blog04122021) on web guiding and web monitoring. There are many exciting developments that will come up this year that your operation will benefit from.

---

# Web Guiding Fundamentals - Rewind Web Guide Structure

URL: https://r2r.tech/blog/web-guiding-fundamentals-rewind-web-guide-structure.md

## Rewind Web Guide Structure



In a previous blog we discussed the unwind web guide structure. Typically, these are made up of a shifting stand, an actuator to move the shifting stand, a fixed sensor mounted on the fixed base of the machine between the last shifting idler roll and a fixed roll, a controller, and of course, the web. Today we look at the rewind web guide structure.



## Rewind web guiding systems act differently than unwind web guiding systems.

 ![Rewind web guide sturcture](https://r2r.tech/sites/default/files/inline-images/Rewind-guiding_1.png)

A rewind web guiding system is not really a web guide. Unlike the unwind web guide, the shifting stand is actually chasing the web. As opposed to the unwind system, [the sensor](​https://r2r.tech/products/roll-2-rollr-sensor?utm_source=blog04262021) is attached to the shifting stand of the rewind, and both idler rollers are fixed to the ground frame. The sensor, therefore, detects the variation in the position of the web. It sends this signal to [the controller](https://r2r.tech/products/roll-2-roll-controller?utm_source=blog04262021). The controller in turn, takes this input and converts it into an output that instructs the actuator to move the shifting stand so the web roll is positioned correctly to the incoming web.



## Rewind web guide systems operate on the premise of maintaining the relative position of the web and the rewind roll.



If the sensor is fixed on the machine frame instead of moving with the shifting stand, we would not know the relative position between the sensor and the rewind roll on the shifting stand. That is why on a rewind web guide system the web position sensor is attached to the shifting stand.

 ![Position of Sensor on Rewind Web Guide System](https://r2r.tech/sites/default/files/inline-images/RewindWebGuideSystemSensorposition.png)

The sensor gives us indirectly the position of the rewind stand. The objective is to make sure that we move the rewind stand so the guide point of the sensor matches the location of the travelling web. This would help in placing the rewind roll at the location of the web so we achieve a properly wound roll.



## The difference between unwind and rewind web guide systems: the position of the sensor in relation to the shifting stand



[Terminal web guides](https://r2r.tech/products/roll-2-roll-unwindrewind-guide?utm_source=blog04262021) have a shifting stand, a web position sensor, an actuator to move the shifting stand laterally, and a controller to process the input from the web position sensor and provide the output for the actuator.



![SCU5 Controller in contrast teaching mode](https://r2r.tech/sites/default/files/inline-images/Controler_burlapWeb_1.jpg)



![WPS Sensor Family](https://r2r.tech/sites/default/files/inline-images/SensorFamily01_0_0.jpg)![Fixed Mount Actuators](https://r2r.tech/sites/default/files/inline-images/RLA-actuators_2.png)




 Follow our weekly blogs on Web Guiding Fundamentals and get more information by [contacting us](https://r2r.tech/contact?utm_source=blog042262021) The main difference between an unwind web guide and a rewind web guide is the sensor position in relation to the sifting stand. In an unwind web guide, the sensor is fixed to the machine frame, while on the rewind web guide, the sensor is attached to the shifting stand. In summary, unwind web guide systems guide the web, rewind web guide systems chase the web and position the shifting stand to the location of the web.

---

# Web Guiding Fundamentals - Sensors

URL: https://r2r.tech/blog/web-guiding-fundamentals-sensors.md

> One of the most important components of a web guiding system are the sensors. If you can't measure, you can't control. If you have a poor sensor and are not able to measure the position of the web properly, it will be impossible to get the accuracy required.



## Common Terminology in Sensors



The terminology used to address sensors in the converting industry is fairly extensive.



- Range, resolution, accuracy, linearity and deadband are terms used for performance qualities of sensors
- Sensor types can be classified by signal emission: infrared, optical, ultrasonic, air.
- Sensor types can also be identified by the feature of the web that is being detected: edge, line, contrast
- Update rate and frequency are terms used to describe how fast the sensor can measure
- Pass line and plane change are terms that are not used on most recent sensor technology, but older ultrasonic sensors will have issues with pass line changes. If the web is too close to the ultrasonic emitter the soundwaves might reflect the sound waves in a way that does not provide an accurate measurement.
- Temperature drift also affects ultrasonic sensors as the piezoelectric crystal used are sensitive to temperature changes. 



**The range of the sensor is the maximum lateral position change that a sensor can measure**. Often in web guiding applications, range is not important mostly because of the fact that you are controlling. However, it is important when you are dealing with web width changes in the line. Range defines how much change in lateral position you can measure with the sensor.



**Resolution is the minimum lateral position change that a sensor can detect.** If you want to guide a web to 0.005" you will require a sensor with a resolution that is 2x to 4x higher than the guiding accuracy.



**Accuracy is an indication of the closeness of the sensor measurement to the real measurement.** This is important for certain types of sensors that are affected by different materials properties such as porosity and opacity.



**Linearity is the consistency of the measurement over the entire range of the sensor**



## Why is sensing important?



### Accurate guiding is impossible with inaccurate sensing



Material properties can affect sensing [accuracy](https://r2r.tech/articles/accuracy-precision-linearity-and-resolution-web-guiding-understanding-terminology?utm_source=blog06142021). As mentioned before, opacity, porosity and reflectivity are some of the web characteristics that will affect certain types of sensors. The environmental conditions can also affect sensing accuracy. Changes in temperature, airflow and the presence of a vacuum can affect a sensors accuracy or make completely inadequate for use. That is what the manufacturers of sensors based on the opposing beam technology have not been able to figure out.



### Opposing beam technology



Most often you will encounter opposing beam sensors. These are commonly called "fork style", "u-shaped" or "horseshoe style." The basic operation of this technology is one arm has the emitter of the signal and the opposing arm has the receiver of the signal. As the web goes in between the two arms it blocks the signal up to the edge of the web. It is a simple principle and it works well in several applications.



The problem with these sensors is that depending the type of sensor there will be occasions in which the web will allow part of the signal to leak through when it is blocking the signal. This will affect the linearity and resolution of the sensor.

 ![Conventional edge detection sensor technology based on blocking and unblocking](https://r2r.tech/sites/default/files/inline-images/Covention-edge-detection-sensor-technology.png)

The signal could be air, sound, infrared light, visible light or uv light. This really doesn't matter. What matters is the material type, whether it is opaque, porous, or reflective. That is why manufacturers will recommend a different sensor based on the web material or the conditions in which the sensor will operate.



#### Disadvantages



As mentioned before, the main disadvantage of sensors based on opposing beam technology is that they are material dependent, and gain change occurs. This the reason calibration is required on sensors that use this technology.



### Fiber optic sensor technology



This technology was introduced to the converting industry by our company in 2014. It has several advantages over the opposing beam technology in that it has higher accuracy and there is no gain change needed. It does provide an absolute measurement, the resolution does not depend on the range, and it is reliable with a variety of different materials. This eliminates the need for calibration due to changes in material properties and environmental conditions.



[Roll-2-Roll Web Position Sensor Demo with Multiple Materials Video](https://www.youtube.com/watch?v=PciZa0LLjX8)





We have much more information on fiber optic sensors, but we will discuss this information in future post. Meanwhile, [contact us](https://r2r.tech/contact) to find out more on fiber optic sensor technology. The following articles provide some in depth information on fiber optic sensor technology:



[The Impacts of the Latest Developments in Sensing Technology](https://r2r.tech/articles/impacts-latest-developments-sensing-technology?utm_source=blog06142021)



[Web Position Sensor Overview](https://r2r.tech/articles/web-position-sensor-overview?utm_source=blog06142021)



Our next blog post will address Controllers for web guiding in the converting industry



If you are interested in getting more information from our knowledge base you can contact us. If this article or any of the other blog posts were interesting to you like us on [facebook](https://www.facebook.com/roll2rolltechnologies), [linkedin](https://www.linkedin.com/company/roll-2-roll-technologies-llc), [twitter](https://twitter.com/@r2r_tech) or [youtube](https://www.youtube.com/r2r-tech).



There is more information we can offer you to help improve your converting process!

---

# Web Guiding Fundamentals - Steering Web Guides

URL: https://r2r.tech/blog/web-guiding-fundamentals-steering-web-guides.md

### Steering web guides are part of the intermediate web guide group.



These differ from the displacement guides in that they don't have a guide span made of two rollers. Steering web guides will typically have one guide roller installed on two raceways at an angle so the roller moves in an arc. The roller upstream from the steering roller is fixed. This arc movement provides the steering of the web.

 ![Steering Web Guides](https://r2r.tech/sites/default/files/inline-images/SG-20-2.png)

### An instant center



For steering guides, a physical pivot point is absent. In this case the web guide system will have a virtual pivot point. A virtual pivot point is the location around which the web guide mechanism rotates. This is also called the instant center. A steering guide requires an instant center based on the arc of the steering roller. This instant center will fall somewhere between the guide roller and the fixed roller that create the entering span.

 ![Instant Center on Steering Guide](https://r2r.tech/sites/default/files/inline-images/Instant%20Center%20on%20Steering%20Guide.jpg)

Because of this arc motion on the steering roller and the fixed roller before the steering roller, the web is subject to bending at the steering roller. This particular type of web guide displaces as well as bends the web as it corrects it's position.



As with the displacement web guide, there is an entry and exit span set to the guide roller. These entry and exit spans have conditions as to the required distance of the span. However, steering guides have to spans at the entry side of the web web and one at the exit.



### Not the first option in web guiding



Steering web guides are not the first choice of guiding solutions, and is not recommended unless it is the only option available. Consider that the bending of the web introduces stresses on the web, especially at the edge of the web. If it is not installed properly, there will be issues with wrinkles, creasing, web tear, and issue with edge quality.



Minimum length of entry and exit span is determined by stiffness of the web, average stress, Young's Modulus and tension of the web, web width, and span length. There is a formula to determine the minimum entry and exit span length and [you can contact us to discuss this formula](https://r2r.tech/contact?utm_source=blog05252021). The entry and exit span do not have to be of the same length.



### Installation considerations

 ![Steering Web Guide Installation Considerations](https://r2r.tech/sites/default/files/inline-images/Diagrams%20for%20%20Steerin%20Guide%20Blog.jpg)

In steering guides, most of the installation considerations deal with the entry and exit span.



1. The exit span must be perpendicular to the plan of motion of the web guide, in this case, the steering roller.
2. As a general rule, entry span should be 1X to 5X the width of the web. Exit spans should be at leas 0.5X the web width.
3. Web stiffness affects the length of the entry and exit spans; stiffer webs will require longer spans (10X for metals) and shorter for flexible webs (1X for nonwoven). There is a formula for determining the minimum span lengths, which we can guide you through.
4. Instant center should be at 1/2 to 2/3 of the entering span length, This is set by the angle of the steering roller sliders.
5. The pre-entry span should be shorter than the entering span.



These conditions come from the dynamic model of steering guides. If these conditions are not included in the installation of the steering guide, you will experience over-steering or under-steering. This will subject the web to unnecessary stresses, and will show up as wrinkles, slack edges or tight edges. 



Additionally, we want to make sure that the angle between the motion plan and the exiting span is 90o, resulting in an exiting span that is perpendicular to the motion plane of the steering roller.



The entering span is usually fairly long and the wrap angle angle around the steering roller made by the exiting span and the entering span should be 90o, but it can by + or - 45o. The same can be said for the wrap angle around the idler roller between the pre-entering span and the entering span, recommended 90o, but + or - 45o is acceptable. Now, bear in mind that by reducing or increasing the wrap angle around the steering roller you are introducing bending stresses on the web through the entering span and the pre-entering span. The result would be moment transfer upstream through the idler roller. This means that the motion of the steering roller could move the web a the idler roller and further upstream. To avoid that we would keep the wrap angle around the idler roller as close as possible to 90o, and the pre-entering span shorter than all other spans in the web guide set up.



As with any web guiding system, we want to have our sensor as close as possible to the steering roller on the exiting span.



### Steering guide installation mistakes



The three most common steering installation mistakes deal with the location of the sensor, perpendicularity of the motion plane and the exiting span, and the length of the pre-entering span in relation to the entry span.



We do not want to place the sensor too far away from the steering roller on the exiting span, or place the sensor on the span after the exiting span. This will lead to understeering and 

 ![Wrong Sensor Location on Steering Guide](https://r2r.tech/sites/default/files/inline-images/Steering%20Guide%20Bad%20Sensor%20Location.jpg)

Additionally, we need to verify that the exiting span is perpendicular to the motion plane of the steering roller. The most common problem faced with this condition is that the web will be subject to bending, and therefore, unnecessary stresses that will result in wrinkles, web tears, and 

 ![Exit Span not Perpendicular to Motion Plane](https://r2r.tech/sites/default/files/inline-images/Motion%20Plan%20not%20Perpendicular.jpg)

###  



###  



### Steering web path options

 ![Web Paths for Steering Guides](https://r2r.tech/sites/default/files/inline-images/Web%20Paths%20for%20Steering%20Guide%20Blog.jpg)

Similar to displacement web guides, steering guides offer an array of web paths to accommodate for specific conditions in a converting line. However, all the installation conditions must be followed for the proper function of the web guide system.



### Summary



#### Design Considerations



As with displacement web guides, the desired correction is the main parameter that needs to be addressed for the proper design of the steering guide. Consider that the movement of the steering roller is limited by the stroke of the actuator and the plane change of the web on the exiting span. The arc of the steering roller is limited to +/- 5o to insure that the web is not too far away from the sensor at an extreme position of the steering roller. Additionally, the raceways upon which the steering roller moves should not exceed an angle of 25o, with 5o to 20o as the preferred range of the raceway angle.



#### Installation Considerations



Steering guides are more complicated to install. Web stiffness will determine the entry span length. The proper entry span length will reduce the chances of wrinkling and unnecessary stresses on the web. The race way angle will determine the instant center location, however, we must make sure that the instant center is located on the entering span within the range of distances mentioned before. Last we must always design our steering guide so the exit span is perpendicular to the plane of motion.



#### Advantages



The main advantage to using steering guides is the reduced cost in manufacturing the mechanism in comparison to other types of guides



#### Disadvantages



At the same time that they are simple and inexpensive to manufacture, steering guides are hard to install due to amount of attention to detail required. Remember the many parameters that have to be considered, such as span lengths, angle of steering roller raceway, 90o angle between exit span and motion plane, etc.



Any deviation from the recommendations presented here will result in poor installation of the web guide, and will create wrinkles, edge stresses and instability in the web.



As mentioned before, wrap angle deviations will also result in traction loss and cause moment transfer and amplification error. 



### Approaching a web guiding solution for your converting operation



Web guiding design is not something that you should embark alone. We are available not only to help you in designing a proper web guide solution for your operation, but also in providing support in analyzing your particular application. It all starts with contacting us to begin the process of solving your web guiding issue.



Our next blog will present other less common web guiding applications that are available to you.



We invite you to follow us on [facebook](https://www.facebook.com/roll2rolltechnologies?utm_source=blog05262021), [linkedin](?utm_source=blog05262021) and twitter to stay up to date on our developments and other instructional materials. [Sign up on our website](https://r2r.tech/contact?utm_source=blog05262021) and get monthly emails on products, applications and developments.

---

# Web Guiding Fundamentals - Summary of Unwind and Rewind Web Guides

URL: https://r2r.tech/blog/web-guiding-fundamentals-summary-unwind-and-rewind-web-guides.md

> Unwind and rewind web guide systems are used at the start and end of the converting lines. That is why they are referred to as terminal web guides. So, what is required to properly incorporate a terminal web guide in your converting line based on web guiding fundamentals?



In previous posts we discussed both unwind and rewind guides. As indicated, they differ in their relationship with the web. Unwind guides require a sensor with its position fixed to the frame of the machine. This allows the sensor to determine the correct location of the web. A controller and actuator help reposition the shifting stand based on the location of the web detected by the sensor as the web is unwound from the roll.



![Unwind Web Guides](https://r2r.tech/sites/default/files/inline-images/Unwind-web-guide_0.png)



Rewind guides use a sensor mounted to the shifting stand. In a sense, the sensor locates the position of the web and through the controller and actuator, repositions the shifting stand to the location of the web. The stand is chasing the web.



![Rewind web guides](https://r2r.tech/sites/default/files/inline-images/Rewind-Guide_0_1.png)



Now that we have the basic knowledge as to how these two types of terminal web guides work, we should understand some [requirements to have an adequate unwind or rewind web guide system.](https://r2r.tech/articles/unwind-and-rewind-guides-design-and-installation-considerations?utm_source=blog05062021)



## Design considerations 



### Mechanical structure rigidity and stiffness



Unwind and rewind stands are moving considerable amounts of weight. The stand not only supports the weight of the roll but also the stand itself. Smaller stands may work with a couple of hundred pounds. However, larger stands are known to handle thousand of pounds. We need to make sure that the mechanical structure of the unwind or rewind has the required rigidity and stiffness, specially when handling a large mass. In general, the rigidity should be such that avoids mechanical resonance of the structure. The natural frequency of the structure should be at least 3 to 4 times the operating frequency of the control system.



### Actuator sizing



![Actuators](https://r2r.tech/sites/default/files/inline-images/RLA-actuators_3.png)



Actuator sizing is one of the most misunderstood parameters in designing terminal web guides. Typically, the total load is the only parameter considered and in many cases the thrust required is overestimated. So, aside from the total load, we also need to consider the static friction to determine the breakaway force required, the desired acceleration, the important factors to consider when sizing an actuator are the required thrust to push the load, and the acceleration needed to reject disturbances and errors. 



### Actuator coupling and stiffness



Just like the mechanical structure rigidity and stiffness we need to make sure the actuator coupling and stiffness are accounted for in the design. Any play or slack in the actuator coupling will reduce the stiffness of the overall system and will destabilize the system.



## Installations considerations of Terminal Web Guides



In term of installation considerations the most important issue is the location of the sensor with respect to the shifting stand. For unwinds, the sensor will be fixed to the machine frame and is independent of the shifting stand. For rewind web guide systems the sensor is installed on the shifting stand and moves with the shifting stand.



## Advantages of Terminal Web Guides



These web guides are simple, and they do not have to take advantage of the normal entry rule. The system deals with parallel rollers and the movement of the web is done by the lateral displacement of the shifting stand. This eliminates the stresses on the web as there is no bending of the web due to changes in the parallelism of rollers as you find on intermediate web guiding systems.



## Disadvantages of Terminal Web Guides



In general, terminal web guides require higher thrust actuators due to the amount of weight that has to be moved. The actuator has to move both the roll of material and the shifting stand. Additional, this type of system is not a good choice if there are high frequency disturbances. In this case, an intermediate web guiding system might be a good option if there is space to install such a system in the line between the unwind and the next critical process or the line and the rewind after the last critical process.



If these considerations are taking into account in the design of the terminal web guiding system, you will have a successful terminal web guiding system in your converting line. In any case, our team of experts are available to help you out in your web guiding system design.



If you are interested in learning more on web guiding and other applications in web handling like our social media page and [sign up for our monthly emails](https://r2r.tech/contact?utm_source=blog05062021).



In our next weekly blog we will address intermediate web guides, starting with displacement web guides.

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# Web Guiding Fundamentals - Terminal Web Guides

URL: https://r2r.tech/blog/web-guiding-fundamentals-terminal-web-guides.md

# The web at the start and end of your converting line needs to be properly aligned to have a good conversion process and a well wound roll for your customers



It's an advantage to know what you are dealing with when aligning your web as it enters your converting process or is being wound into a processed roll. Here's some information that should be of help to you.



## Web guides can be classified by their location on the converting line



There is a terminology for web guides based on their location within the converting line. Web guides that are at the unwind or rewind stands are referred to as Terminal Web Guides. Web guides that are located within the converting line, right before a critical process, are referred to as Intermediate guides.



## Terminology to identify terminal web guides 



Terminal web guides are used at the entry and exit of the converting machine. They are referred to as **shifting stand, shifting base, shifting base, shifting sidelay, roll positioning stands, uncoil/recoil, payoff and tension reel, unwind guide and rewind guide**. These last two terms are the most commonly used in the converting industry, but it is important to know all the other terms for identifying terminal web guides.



## Difference between unwind and rewind web guides



Even though both unwind and rewind guides have the same components, the location of the sensor for edge or contrast guiding will differ. In the case of unwind web guiding systems, the sensor is located on a fixed point on the converting machine or the frame of the fixed frame of the unwind. The reason for this is that at the exit of the unwind stand, you want to position the web based on a fixed reference on the converting line. Your intent is to correct any winding defect on the roll, including misplacement of the roll on the unwind.

 ![Unwind guide system](https://r2r.tech/sites/default/files/inline-images/Unwind-guiding_0.png)

For the rewind side of the converting line, the sensor must be mounted on the shifting frame of the rewind. In this case, the winding roll chases the position of the web. so it technically is not guiding the web but the shifting stand to correctly position the web on the rewind roll.

 ![Rewind guiding installation](https://r2r.tech/sites/default/files/inline-images/Rewind-guiding_0.png)

## An alternative guiding system for terminal web guides applications



There will be cases where the unwind and/or rewind stand is fixed. In that case the web must be guided to the required position. You have two options, convert your fixed unwind or rewind into a shifting stand, or install an intermediate guide ([displacement](https://r2r.tech/products/displacement-guides?utm_source=blog03302021) or [Steering Guide](https://r2r.tech/products/web-guides/steering-guide)(https://r2r.tech/products/roll-2-roll-steering-guide?utm_source=blog03302021)). If there is enough space and the stand is close enough to a critical process in the converting line, you could use a displacement or offset pivot guide, or a steering guide. You would pick the intermediate guide based on the probable entry span length resulting in your process. This is discussed in a future Fundamentals post.



Unwind and rewind guides are discussed in more details in our article ["Unwind and Rewind Guides: Design and Installation Considerations"](https://r2r.tech/articles/unwind-and-rewind-guides-design-and-installation-considerations?utm_source=blogpost03302021)

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# Web Guiding Fundamentals - Unwind Web Guide Structure

URL: https://r2r.tech/blog/web-guiding-fundamentals-unwind-web-guide-structure.md

**Within the group of terminal web guide systems, there are two basic types: [Unwind web guide systems and rewind web guides systems.](https://r2r.tech/products/roll-2-roll-unwindrewind-guide) **



Both systems have basically the same components, but they work differently. Let’s look at the unwind web guide structure.



![Unwind Web Guide Structure](https://r2r.tech/sites/default/files/inline-images/Untitled%20presentation.jpg)
 The unwind web guide structure has a parent roll, or unwind roll that provides the web that will go into the converting process. It is mounted on a shifting stand and it is supported by bearings, in most cases, linear bearings. The motion of the shifting stand is provided by an actuator that is installed with one end on the moving stand and the other end to the fixed based of the unwind stand. Finally, there is a sensor for edge or line detection that is looking at the position of the web downstream of the unwind.



## The main objective of the unwind web guiding system is to insure that the web is at the desired location.



In the case of an unwind system, the sensor has to be fixed to the machine frame. It does not move with the shifting stand. The motion of the shifting stand will be perpendicular to the direction of the web. As with all web guiding systems, the feedback from the sensor will be used by the controller to move the actuator in a way that will correct the position of the web.



## Location of the sensor



The diagram of an unwind web guiding system shows a shifting idler and a fixed idler. The shifting idler is mounted on the shifting stand. The fixed idler is mounted on the fixed frame of the unwind or of the converting machine. 



![Sensor Placement Between Fixed and Shifting Idler](https://r2r.tech/sites/default/files/inline-images/SensorPositionBetweenIdlers.png)



The sensor is positioned between these two idlers. The main reason for doing this is that the web plane will remain constant during the unwinding process, and the sensor will provide an accurate reading of the location of the web. Now, the sensor could be positioned between the unwind roll and the shifting idler. However, if the sensor is at this location, the distance from the sensor to the web, or the web plane, will change as the web roll changes in diameter. This will affect the guiding performance. 



## The Shifting Idler on an Unwind Web Guide



In an unwind web guiding system the shifting idler can have several configurations. Even though in the graphic the idler roller is represented as one roller, the shifting idler assembly can have a setup of two or more rollers. In some cases, there might be a set of several rollers on the shifting idler assembly. The important thing is that the sensor has to be positioned after the last shifting idler, as close as possible to the last shifting roller. This will provide the controller with the best feedback on the position of the web from the sensor.



A rewind web guiding system works different in the way the sensor is position with respect with the shifting stand. This will be discussed in the next post on Web Guiding Fundamentals. We have more information regarding web guiding and web sensors for width measurement and monitoring and it's all at your disposal. [Sign up at our website](https://r2r.tech/contact) for our articles and videos, and future technological developments.

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# Web Guiding Fundamentals - Web Guide Actuators

URL: https://r2r.tech/blog/web-guiding-fundamentals-web-guide-actuators.md

So far we have discussed the different types of web guiding systems for converting applications. You now should know the different types of web guiding systems, and their design and installation recommendations. Also, you should have an idea of why web guiding is needed and where they should be installed in converting operations. In this blog post we will address a component of a web guiding system, the web guide actuators.



> Web guides have four main components: actuator, web guide mechanism, controller, and sensor. All four work together to place the web in the desired location. The actual movement of the web guide mechanism is performed by the actuator.

 ![Electromechanical Actuators](https://r2r.tech/sites/default/files/inline-images/actuators1.png)

Actuators provide the driving force to move the guide structure which in turn positions the web



## Terminology used for Actuators



When speaking about actuators you will find certain terms that are part of the selection or sizing of actuators:



- Thrust and power - is the actuator capable of moving the total load, considering the friction between bearings and raceways supporting the side-lay or carriage, and through what distance?
- Speed and acceleration - how fast can the actuator move the load, stop it, and change direction?
- Stroke length - how far does the actuator shaft extend from its completely retracted position?
- Mounting/Coupling - threaded rod, spherical rod/rear eye, rod/rear clevis. pivot eye or eye bolt, trunnion?



## Hydraulic or Pneumatic Actuators



Older actuators are either hydraulic or pneumatic actuators. Hydraulic actuators require a hydraulic power unit to supply the fluid that would move the shaft of the cylinder in or out of the cylinder. These units and actuators were common in the 50's up to about the 90's, mostly because the could provide the hydraulic pressure required to move the cylinder or actuator to displace heavy loads.

 ![Pneumo-hydraulic actuator](https://r2r.tech/sites/default/files/inline-images/Power-Unit_0.png)

During that time the technology of electromechanical actuators was not advanced enough to provide a reliable actuator to move heavy loads. Pneumatic actuators have the advantage that they can be used in locations where hazardous environmental conditions do not allow the use of any type of electrical equipment or heat producing devices.



However, these two types of actuators do have certain issues in industrial operations. Hydraulic actuators still had issues with precision and presented the risk of contamination from hydraulic fluid leaks. Additionally, these units have a higher maintenance cost of both the cylinder and the power unit, and are extremely noisy.

 ![Hydraulic Leak on Pneumo-hydraulic Power Unit](https://r2r.tech/sites/default/files/inline-images/PowerUnitLeak-01_1.png)

Pneumatic actuators require large cylinders to have the same thrust and power as hydraulic or electromechanical actuators, and can have issues with precision with temperature changes and high loads, as air is a compressible gas.



## Electromechanical Actuators



The introduction of electromechanical actuators in the 90's solved many issues in the converting industry. The improved designs today present greater precision and lower maintenance cost. Most important, they are capable of moving very high loads with precision and efficiency.



Most web guides today use electromechanical actuators. Typical electromechanical actuators will have a motor that drive a gear belt using a pulley. Another pulley is connected to a lead screw, ball screw or roller screw where the rotary motion is converted into linear motion at the rod end of the actuator.



## Terminology in electromechanical actuators



Electromechanical actuators have another list of terms that allow for proper selection:



- Current, voltage and power - what is the maximum?
- Pitch/lead and gear ratio - this information is required when converting rotary motion into linear motion using pulleys and timing belts.
- Backlash and resolution - low end lead screw actuators deal with backlash, and resolution is the smallest movement that an actuator can produce.
- Backdrive - usually deals with web guides that have to work against gravity.

 ![Rear Clevis Mount Actuator](https://r2r.tech/sites/default/files/inline-images/rp-actuator_0.png)

Types of actuators are identified by the following



- Inline and reverse parallel
- Limit switch/End stop
- Motor - Servo, stepper, brushed and brushless



## Sizing Web Guide Actuators - Factors



When determining which actuator to use in a web guide design there are certain factors that are required to select an actuator that has the appropriate thrust and stroke required for the application.



- Web line speed - the maximum disturbance frequency that can be processed is dependent on the web speed. The higher the speed web speed the higher dynamic response needed from the actuator. The dynamic response is related to the acceleration and the acceleration is related to the thrust, that's why web speed becomes important
- Guide structure weight + roll weight (for terminal guides) - knowledge of the magnitude of the mass that will be moved is necessary.
- Bearing friction (dependent on type of bearing) - roller or precision linear bearing have low friction, if they are new or in good shape. Sliding surfaces have higher friction
- Break away force - what is the force required to get the guide structure in motion, most important in terminal guides. This is determined by the coefficient of friction of the bearing
- Disturbance magnitude and frequency - this is mostly unknown. There is an amount of disturbance that can propagate through the converting machine and it is dependent on the speed of the web. The faster the web the higher the disturbance frequency, so the web acts like a low pass filter.
- Desired acceleration - this is the desired response time. Note that as lower web speeds are processed the desired acceleration will be less.
- Type of guide structure installation - here we are most concerned on whether gravitational effects need to be considered based on how the web guide structure will be installed.



Actuators are now fairly straight forward in designs and capabilities. As a converter, all you will need to do is answer a few questions from the supplier to determine the best actuator for your operation.



In our next blog post we will talk about sensors for web guiding applications. We hope this information is of use to you and the personnel in your operation. [We can help you in determining the best actuator for your web guiding application](https://r2r.tech/contact?utm_source=blog06092021), along with any other issues you might have with a web guiding solution for your converting process. You can follow us on [facebook](https://www.facebook.com/roll2rolltechnologies), [linkedin](https://www.linkedin.com/company/roll-2-roll-technologies-llc), or [youtube](https://www.youtube.com/r2r-tech) to stay informed on applications, products and technical information.

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# Web Guiding Fundamentals - Web Guide Controller

URL: https://r2r.tech/blog/web-guiding-fundamentals-web-guide-controller.md

So far, we have looked at the web guide mechanism, actuator and sensor. The remaining component of a web guiding system is the web guide controller. 



> ### The controller is the central processor that takes the sensor input and computes the proper corrective action for moving the web guide. 



Every guiding system requires a [controllers](https://r2r.tech/products/roll-2-roll-controller?utm_source=social06232021). It is, after all, the processor of the input and output signals that come from the sensor and go to the actuator. Initially, simple controllers had knobs, buttons and lights to help calibrate the sensor and actuator. Initially, controllers had operator interfaces with buttons and knobs for selecting menus and calibrating controllers and sensors. However, these were difficult to navigate and required manuals for instructions on using these options. Most handled analog electrical or pneumatic analog signals. Today, controllers have evolved to include a human-machine interface, most likely an operator interface with screen input and feedback, to allow operators to set parameters, select options and view current status of the system..  

 ![Controller with Sensor](https://r2r.tech/sites/default/files/inline-images/Copy%20of%20Controler_burlapWeb.jpg)

### Terminology for Web Guide Controller



As with all elements in the converting industry, there are certain terms that you run across when dealing with controllers. Gain is the most commonly used term and it deals with how quickly or what kind of dynamic response is needed. Operating voltage and power consumption refer to the power requirement of the controller. As mentioned before in this post, Human Machine Interface (HMI) or Operator Interface (OI) indicate the availability of operator handling of the controller. Today, user friendly screens are a great step forward in creating systems that are simple and easy to operate. The type of driver/drivers the controller has depends on the type of actuator, is it for a stepper motor or a servo motor. Controllers might have one sensor input port or several. In some cases, connectivity such as Ethernet or Profinet is desired and/or remote control capability.



### Fixed Gain Proportional Controller



Most web guide control systems have structure where you have a fixed gain proportional control. The proportional control is probably all you need in a controller for a web guiding system because the integration operation is built into the system. Usually you have a motor, a current loop, a velocity loop with a tachometer, a guide structure with its own transmission ratio, and the web dynamics which are unknown. The web dynamics refers to how the web moves if the web guide moves a certain amount. This depends on transport conditions, stiffness of the web, tension, and other web characteristics. Finally, you have the sensor that measures the edge position and transmits the information to a position controller that drives all the loops. This is a fairly simple architecture for web guide controllers.

 ![Controller Structure](https://r2r.tech/sites/default/files/inline-images/Untitled%20presentation_0.jpg)

Web guide proportional controllers are fixed gain and most often are detuned for the conditions. To get the optimal performance you would have to tune the controller because of the unknown web dynamics. Most often DC motors, DC servo motors, and DC stepper motors are used with this controller structure.



### Model Reference Adaptive Control



There other advanced control technologies such as adaptive control where the controller adapts or learns on the fly. Tuning may not be required. Learning on the fly means it adapts to sensor gain changes or the dynamics of the web

 ![Model Reference Adaptive Control](https://r2r.tech/sites/default/files/inline-images/Model%20Reference%20Adaptive%20Control.jpg)

### Advanced Stepper Control Structure



In our case, we have a fairly similar structure as the fixed gain proportional controller. However, it has some motion control aspects built into it, in term of s-curving the position, and having trajectories for velocity. We can increase the stability of the controller and provide fairly aggressive output performance. Again, it is pretty similar to the fixed gain proportional control with a current loop, a position loop if you have an encoder, the position of the actuator, and the web position which would include the web dynamics.

 ![Control Structure](https://r2r.tech/sites/default/files/inline-images/Control-structure-roll-2-roll.png)

### Open Loop versus Closed Loop Step Response



You've probably heard of non-feedback and feedback control systems. This is another form of identifying open loop and closed loop systems. Open loop systems do not measure the output signal and is not fed back to the controller for comparison with a set point in the system. Closed loop systems have the ability to self correct as it's out put is affected by the signal input an the correction calculated by the control. We have done tests in our lab with a web guide system using an open loop system. Even though web guide system slowly attempts to correct the web location, it is very dependent on the web velocity and is not very responsive. The same test with a web guide with a closed loop system is much more effective and achieves a stable output fairly quickly.



### Characteristics of a good controller for a web guiding system



When discussing what is desirable on a controller for a web guiding systems we have a few main features. It should a good dynamic response, that is the ability to attenuate disturbances on the web guide. It should be easy to tune, or better yet, require no tuning. Obviously, it should be stable and should have fast processing power in order to process multiple sensors. With the new converting machine designs, manufacturers and end users alike seek industrial Ethernet connectivity for advanced functionalities. Another desirable feature of modern controllers is an intuitive operator interface. In general, converting operations are moving toward user friendly systems that allow for fast navigation through menus and easy to understand icons. Finally, as greater advances are achieve in automation, OEMs are adopting more AI into their systems as the converting industry works to include industry 4.0.



Our next blog on fundamentals of web guiding will address Guiding Performance.



We hope that this series is of benefit to you and your operation and keep following our posts.



If you have any questions or would like additional information on our technology, products or just general web guiding [contact us!](https://r2r.tech/contact?utm_source=social06222021)

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# Web Guiding Fundamentals - Web Guiding Performance

URL: https://r2r.tech/blog/web-guiding-fundamentals-web-guiding-performance.md

We have reviewed all the major components of a web guiding system, sensor, web guide mechanism, actuator and controller. However, the question still remains what is a good web guiding system? For this we have to address web guiding performance



> #### Speaking of web guiding performance, how accurately can you guide a web? Well, it depends...



Web guiding accuracy depends on many parameters that affect such accuracy.



## Errors



### Steady State Error



If we are dealing with a steady state error, we can expect an error within +/- 0.5mm with a perfect machine and perfect material. Steady state error is the difference between the desired value and the actual value of a system. It is possible to achieve a better performance, such as is required for flexible printed electronics (this will be discussed in a future post, or you can contact us for an in person discussion), but for a typical converting operation with ideal conditions of machine and material the afore mentioned error is expected.



### Transient Error



Most web guides are going to experience transient errors. Transient errors are based on disturbances that may be caused by web material properties or other environmental conditions in the converting process. When correcting transient errors you have to consider the magnitude and frequency of the error. Additionally, transient errors can propagate downstream of the sensor. Even though the error is corrected at the sensor, you don't know the angle at which the web is approaching and that can cause waves downstream.





### Wrinkles, edge curl and flutter, and plane change



Also, you won't have good guiding performance if you have wrinkles on the web. A wrinkling web will cause the edge to move back and forth. Edge curl or [flutter](https://r2r.tech/articles/new-sensor-web-flutter-measurement), and web plane change will also affect guiding performance.



### Magnitude errors



If you are facing large magnitude errors and the stroke of your actuator is limited, or the correction of the web guide can provide is limited then you can't expect good web guiding performance if the actuator is topping out on either side of its stroke.



### High Frequency Errors



Guiding performance is also negatively impacted it you are using a lower bandwidth actuator and you are facing higher frequency error. As the frequency increases beyond the bandwidth of the actuator, the performance declines.



### Sensor Accuracy



If the sensor accuracy or the gain change is poor you can't expect appropriate guiding performance. The correction of the web position basically starts with knowing where the web is in the first place



### Improper installation



Error can be amplified by an improperly installed web guide system. In previous post we presented how departure from the 90o wrap around the guiding rollers, or improper location of the sensor can have negative effects on the web guiding performance of a system.

 ![INstallation Mistakes](https://r2r.tech/sites/default/files/inline-images/offset_pivot_guide_installation_mistakes.png)

## Factors affecting web guiding



The factors affecting web guiding can be summarized in four areas: Machine related, involving web guide installation; process related, involving traction and tension, and magnitude of error with respect to the stroke of the actuator; material related, wrinkle and curl, and bagginess; and web guide related, rate of error with respect to actuator speed, acceleration and thrust, sensor deadband and actuator backlash, correction and stroke limits



## Guiding system design requirements



A good web guiding system design relies on good parameter information. Basically, you need to have knowledge of the web speed, limitations in location and installation, web properties such as web thickness and stiffness, environment in which the system will operate, tension and loading on the web, desired response and accuracy, desired correction and stroke length and expected error magnitude and rate. This is information that we try to obtain from our customers when we are helping them determine the appropriate web guiding application for their converting line.



> ### Web guiding performance can be improved with good knowledge of the process, materials and machine



Our blog series on web guiding fundamentals will wrap up in our next blog post with a summary of web guiding fundamentals. As always, we invite you to contact us if you have any question regarding web guiding and web monitoring. 



Sign up for our monthly emails with information on applications, technology and new developments in our field.

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# Web Guiding Fundamentals - Why We Need Web Guides

URL: https://r2r.tech/blog/web-guiding-fundamentals-why-we-need-web-guides.md

A customer once asked us why would you need web guiding on a brand new machine? Their point of view was that the machine was state of the art, the web guide didn't move at all during operation, and they didn't see any problems with their materials. Well, our answer was that there are four main reasons why any converting line requires web guides.



- Materials are not perfect
- Machines are not perfect
- Processes are not perfect
- Operators are not perfect



### Materials are not perfect



When dealing with materials in converting, the first thing we need to consider is that the material already comes from a previous process. A typical issue that converters face are poorly wound rolls. This could be the result of tension control issues from the supplier of the roll. However, this condition might be detected or not.

 ![Examples of Incoming Rolls](https://r2r.tech/sites/default/files/inline-images/Examples%20of%20incoming%20roll%20issues_0.png)

Then, you might have to process a roll that has been deliberately oscillated during the roll process. This is usually seen in operations where the material has a border that differs in thickness from the rest of the web, such as in lamination or coating processes. Material thickness variations might be present from the natural manufacturing process of the roll. These gage band variations can occur across the width of the web. These thickness variations can cause the web to track or slide differently, causing slight changes in position of the edge of the material. A poor splice that causes step or angular misalignment might be present at the joining of the end and start of rolls which can cause a sudden misplacement of the edge of the web. Additionally, some materials might have a natural curvature, which is also known as camber.



### Machines are not perfect



One of the most common reasons for webs not travelling properly has to do with the rollers on the machine. Out of round rollers will affect the behavior of the web. Out of round could be rollers with excessive eccentricity, variations in roller diameter across the length of the roller or roller profiles with excessive camber. Additionally, rollers might be misaligned with the other rollers in the machine causing the web to track side to side



Converting machines can also have issues of poor tension control. When the web does not have enough tension, it will have issues of tracking through the machine. Acceleration or deceleration of the web will also affect how the web tracks through the machine. 



### Processes are not perfect



A web that presents gauge variations, which could be caused by coating or lamination issues, will have issues with miss-tracking. Another factor, specially with higher web speed conditions is air entrainment between the roller and the surface of the web. The air in between these two components will create a film that will reduce the friction and therefore allow for slippage of the web on the rollers.



### Operators are not perfect



Splicing requires a precise alignment of two webs and holding them together with a splicing tape. However, precision does not occur often and it will be necessary to provide a web guiding system. Also, operators might not position a new roll at a precise location on an unwind stand. This will create a need to constantly guide the material to maintain it in position with the machine.



Because of all this conditions, web guides are necessary at different locations of a roll-2-roll machine just before the process that requires web alignment. 



Every year we present webinars related to web guiding and web monitoring. To get more information as to when these will be held and attend, just [contact us](https://r2r.tech/contact) and tell us that you would like to get more information on signing up for our webinars. Read more in our article: [Web guiding system: Why, What, Where and How?](https://r2r.tech/articles/web-guiding-system-why-what-where-and-how)

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# Web Guiding Monitoring - Roll-2-Roll Technologies LLC at Converters Expo 2022

URL: https://r2r.tech/blog/web-guiding-monitoring-roll-2-roll-technologies-llc-converters-expo-2022.md

Yes, we skipped exhibiting at Converters Expo last year, but we are back. After the hiatus in trade show attendance, it’s good to see Converters face to face. Better yet, we enjoy helping Converters solve problems that might seem unsolvable. 



This year we are sending two of our experts to work with you in solving your problem in web guiding and monitoring. Whether it’s an issue with edge, center or line guiding in a specialty area, or a difficult monitoring application, we have developed the technology to solve many problems in the industry.



This is the opportunity for you to see the new developments in web detection with linear cameras. We will showcase web guiding systems and web detection using edges or contrasts. One thing you might want to see for yourself is the low profile of the sensors. They can be placed in locations on your line where no other sensor can. 



Our team is also going to take some time during the week to visit customers and other Converters that would like to see what the future of web guiding brings. Contact us at the show or through our website If you are in the region and would like for us to evaluate your problem.



If you want to [attend the Expo we can offer you a discount on your registration. Use Code CE22R2RVIP to get the discount.<](https://r2r.tech/events/roll-2-roll-technologies-llc-converters-expo-2022-0?utm_source=blog041822)



[ ](https://r2r.tech/events/roll-2-roll-technologies-llc-converters-expo-2022-0?utm_source=blog041822)

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# Web Guiding Upgrade Applications

URL: https://r2r.tech/blog/web-guiding-upgrade-applications.md

## Web Guiding Upgrade Applications



### Imagine running a converting operation that has multiple converting lines. Each of these lines has been in operation for at least 20 years. You have invested in many improvements to the line, but are now faced with aging web guiding systems that are starting to fail.



At first, you manage to work with the deficiencies they have. However, now the web guides are starting to fail and one by one are being placed out of operation. Worst yet, your customers are requiring better quality from your line and these aging web guides are hindering your effort to provide improved quality. So, why haven’t you repaired those aging web guides?



When asked this last question most converters will answer that the manufacturer of the web guide on their line for the past 20 plus years no longer manufactures that model. Worst yet, they no longer provide spares or service to them. There seems to be only one answer: buy a new web guide… or is that so?



Web guides are made of four main components: web guide mechanism, controller, sensor, and actuator. Of these four components, web guide mechanisms are the easiest to maintain or repair.



Typically, it will require changes in bearings, rollers, mechanical connectors and fasteners to get it back in good working condition. The other three components provide the hardship to converters. These are the elements that become obsolete with time. The obsolescence of a technology means that the element is no longer manufactured, and that parts are no longer available for repairs. 



## Our solution is the web guide upgrade kit.

 ![Upgrade Kit for Discontinued Web Guide Systems](https://r2r.tech/sites/default/files/inline-images/Retrofit%20Kit2_0.jpg)

An upgrade kit consists of a controller, sensor, actuator and motor driver. With these components your old, obsolete web guide comes back to life. Not only do you get more years of operation, but you also have a web guide with the latest advances in converting technology. So let’s talk about the different upgrade applications available.



Upgrades of obsolete web guiding systems, pneumo-hydraulic units, and unwind/rewind web guides.



We see these old web guides all the time when we travel through the US visiting different converting operations. North American, General Web Dynamics, Arpeco, and current brands with obsolete models, are just a few of the web guides we find that are still on a line, but are not operational. The mechanism is in working condition or can be repaired, but the controller, actuator or sensor are not operational and there are no spares.



The same thing happens with pneumo-hydraulic web guides and terminal web guides for unwind and rewinds. In some cases there are no spares or services. In other cases, there are issues of product contamination, lack of precision, and costly maintenance.



The solution for all these problems is the upgrade web guide kit. You keep your web guide mechanism and we help you replace the controller, sensor, driver and actuator with a more advanced technology, all at a fraction of the cost of replacing an entire web guide system. 



#### Read about how one of our customers used our upgrade kit and the problem it solved for them



## A simple four component solution



An upgrade web guide kit will have an SCU5 controller, a WPS sensor in models with sensing ranges from 48 mm to 900mm, a motor driver and actuator. Depending on the application, you might need a mounting bracket for the actuator or a high thrust actuator to move high loads such as you would encounter in unwinds and rewinds.



An upgrade kit for these types of guides will consist of a SCU5 controller, a WPS sensor that in models with sensing ranges from 48 to 900 mm, a driver, and an actuator. These are simple to install and operate and there is plenty of documentation and videos for these applications.



## Upgrading old web guides



Old web guides with electromechanical controls and actuators are fairly simple to upgrade. It will require disassembling the web guide mechanism to access the location of the actuator Of course, we will need to talk to you about the application and parameters to properly size the actuator and to give you the solution that best fits your needs. The controller can be placed anywhere on the line in a safe location for the operator. The sensor has to be close to the web guide after the exit roller of the guide. The driver can be supplied with various cable lengths to allow it to be placed in a convenient location within your converting line. As mentioned before, the installation of the mechanism requires the disassembly of the web guide mechanism. If you have a maintenance crew in your operation you can do this at your facility following our instructions. [We have videos demonstrating the steps for the replacement of the actuator for several types of web guides](https://r2r.tech/videos/how-upgrade-north-american-web-guide-actuator-replacement). In any case, we also offer the service of doing the upgrade at our facility.

 ![Upgrading a North American Webguide](https://r2r.tech/sites/default/files/inline-images/HowtoupgradeaNorthAmericanwebguide.jpg)

## Upgrades of pneumo-hydraulic web guide systems



[Pneumo-hydraulic web guiding systems](https://r2r.tech/articles/pneumo-hydraulic-web-guides?utm_source=blog02022021) were required at one time because of the need of high thrust at the actuator. Now, with the advances in electro-mechanical actuators that provide very high thrusts, you now have access to a more advanced web guiding technology. No more need for hydraulic power units or pneumatic systems for sensors and controllers to actuate the web guide. No more worries about possible hydraulic leaks that can contaminate your product or create safety hazards in your converting lines. As with the upgrade of electromechanical units, the controller, driver and sensor are the same. The actuator might require a mounting bracket to install in the location of the old hydraulic cylinder. We already have bracket designs for several web guiding systems that are ready to mount. However, as in all applications we will discuss with you the application and the current model of web guide you have installed to determine the proper upgrade, including the mounting brackets.



## Upgrades of terminal web guide systems for unwinds and rewind



An unwind or rewind can have a fixed carriage or a laterally shifting carriage. The fixed carriage type unwind or rewind guide will use an intermediate web guide. The web guide would only require an actuator with enough thrust to move the web. Therefore, it is only dependent on the web tension and the web speed. If the converting line already has a web guide that is not working, then a web guide upgrade kit should solve the problem.



A shifting carriage unwind or rewind requires an actuator that can handle the weight of the carriage and the maximum roll weight to be handled. This requires an actuator with enough thrust to move the carriage and roll. However, one must also consider the thrust required to change the direction of the stand with the maximum roll weight. Again, this is an application that requires discussion on the application in order to determine the best actuator for the application. Regarding the controller, sensor and driver, these are basically the same as for other upgrade applications.

 ![Unwind guiding system with a fixed sensor and a moving idler](https://r2r.tech/sites/default/files/inline-images/Unwind-guiding.png)![Rewind guiding installation with a moving sensor](https://r2r.tech/sites/default/files/inline-images/Rewind-guiding.png)

**If you like this post and are interested in keeping up with our developments and applications, [contact us and sign up](https://r2r.tech/contact?utm_source=blog01112021)for our monthly email edition. We have tons of web guiding and monitoring knowledge that we would like to share with the converting industry. Better yet you can [schedule a live demo](https://r2r.tech/schedule-live-demo?utm_source=blog01112021)of our product line based on your particular application.**

---

# Welcome to our blog posts - our mission is to educate and facilitate access to web guiding and monitoring technology

URL: https://r2r.tech/blog/welcome-our-blog-posts-our-mission-educate-and-facilitate-access-web-guiding-and-monitoring.md

### When we started Roll-2-Roll Technologies over five years ago...



we had an idea in mind as to how we would change the industry. Our technology for certain is a game changer in the industry. We introduced a sensing technology that separates itself from any of the traditional philosophies of edge sensing designs: a sensor that can detect any kind of material and deal with changing environmental conditions without calibration, and a single sided sensor that departs from the fork style design so that it occupies less volume and can be fit in restricted spaces.



However, our mission statement has two main tenets to how we approach converters and future customers. One, we want to provide simple solutions to even the most challenging problems. We want your technical and operations personnel to feel comfortable with our technology. This will allow them to take fewer steps to set-up a web guiding or monitoring system. Your operators and technical staff will get readouts and outputs in an easier fashion. Converters will save time, materials and money. Two, we want to democratize access to technology. Our idea is to teach people in the converting industry how webs behave, how web guiding works, how our sensor technology simplifies the converting operation. We want anyone that is interested to have a working knowledge of web guiding and monitoring applications.



How are we going to do this? By giving you access to articles, videos, live online demos, etc. All you have to do is ask.



Additionally, we will also work on posting blogs on general issues that affect general converting. Last year we would have never envisioned an industry without personal live contacts, but that is exactly where we are. Most companies have adapted to a giant change in how we get our information and products to customers. Companies that learned how to handle the new conditions of doing business and proactively acted on it, are now seeing the fruit of their labor. Is this a permanent condition? We don’t believe so, but we do know that the change has made us more creative. This is the part that we hope remains with the industry after all is past us. So, we look forward to sharing our views on web handling technology with you and we will work hard to make this worth your while.

---

# What is a line scan camera and how does it compare to Roll-2-Roll® Sensor?

URL: https://r2r.tech/blog/line-scan-camera-vs-roll-2-roll-sensor.md

In a [previous blog post](https://r2r.tech/blog/roll-2-rollr-sensor-just-sensor) we saw how [Roll-2-Roll® Sensor](https://r2r.tech/products/sensors) is not just a simple sensor but more like a [vision based system that is simpler to use](https://r2r.tech/blog/roll-2-roll-sensor-vs-vision-system). Specifically we saw that they are more like a [1D line scan camera](https://r2r.tech/blog/roll-2-roll-sensor-vs-vision-system). In this blog post we will dig deeper into line scan camera technology to compare the [Roll-2-Roll® Sensor technology](https://r2r.tech/articles/fiber-optic-sensor-web-edge-detection) with typical line scan cameras.



## What is a line scan camera?



As the name suggests, line scan camera is a one dimensional camera with the imaging element (pixels) arranged on a single line. Unlike most cameras where the image captured is a two dimensional (2D) image, line scan cameras capture one dimensional (1D) image. A 2D image is created from a 1D image capture by either moving the camera or moving the object. Hence line scan cameras are commonly used in inspection of continuously moving objects such as inspection of a web or inspection of objects on a conveyor belt. By aligning the one-dimensional array perpendicular to the motion of the object the whole image of the object is created one line at a time. Each line is captured and integrated to form a 2D image by synchronizing the each image capture based on the speed of the moving object or the web speed (usually with an encoder).

 ![Illustration of a 1D line scan camera](https://r2r.tech/sites/default/files/inline-images/Line-Scan-Camera.png)

## Advantages of line scan cameras for roll-to-roll inspection applications



Compared to a 2D frame camera, line scan cameras have several advantages for inspection of continuous moving objects or inspection of products on roll-to-roll machines.



- The exposure time with a 2D camera should be short (compared to the web speed) in order to capture the image without blur. Defect detection for high speed applications (over 2000 fpm or 10m/sec) are not possible with an affordable 2D frame camera. On the contrary 1D line scan cameras are extremely fast with scan rates of over 200 kHz or 5 microseconds per line enabling high speed defect detection.
- With a line scan camera the lighting for the camera can be concentrated along a line rather than a rectangular region, thereby reducing the illumination cost. Additionally, lower exposure time with a 2D frame camera requires high power external lighting adding to the overall cost.



## Line scan camera types and specifications



Within line scan technology there are several different types of cameras based on the image sensor technology: [CMOS (complementary metal oxide semiconductor)](https://en.wikipedia.org/wiki/Image_sensor#CCD_vs._CMOS_sensors) or [CCD (charge coupled device)](https://en.wikipedia.org/wiki/Charge-coupled_device). The image sensors also have different resolutions based on the number of pixels in the camera and the closeness of the pixels (pitch between the pixels). Common pixel counts range from 512 pixels, 1024 pixels to up to 16K pixels while the pixel pitch ranges from 5 µm (1µm = 0.000001 m = 1e-6 m) to 14 µm. Finally, the scan rate is another common specification that is important for line scan cameras with typical line scan rate of 5 kHz to 200 kHz, i.e., each line of image is captured even 200 microseconds to 5 microseconds.



## Optics for the line scan cameras



The real world application requirements are translated into above specification requirements for the image sensor with a proper choice of optics or lens for the camera. Circular lens optics is the most common type of lens used by line scan cameras. Circular optical lenses enable the camera to capture an object much bigger than the camera sensors by focusing the image on the camera sensor with certain magnification (or demagnification). The focal length and magnification of the lens is chosen based on the number of pixels in the camera, the size of the object or desired field of view and the minimum feature size to be detected. And the relationship between the working distance, focal length and the magnification is as follows: working distance = (focal length) x ( 1 - (1/magnification)).

 ![Field of view and working distance](https://r2r.tech/sites/default/files/inline-images/Field-of-view.png)

## Problems with conventional optics



### Smaller Pixel Size to accommodate standard lens



Circular optics, typically designed and paired with for 2D image sensors, are also used with 1D line scan cameras. Standard lens mounting option like a C-mount option is typically used with line scan cameras. More expensive lens mounts such as T-mount and F-mount are also used with higher pixel count line scan sensors. The standard mounting options not only define the maximum lens diameter but also the flange focal length.



When the pixel count increases, the overall size of each pixel is typically reduced so that standard camera mounts can be used. For example, the C-mount lens with mounting thread diameter of 1 in or 25.4 mm cannot be used with any line scan camera with line length more than 20 mm. With 2K pixels the size of the individual pixel (pitch) should be no more than 9 µm in order to use a C-mount lens. Likewise with 8K and 16K lines the pixel size has to be limited to 5 µm so that a F-mount or a T-mount lens could be used. As the pixel count increases the pixel size gets smaller to ensure that standard lens mounts can be used since medium format lenses are very expensive.



With smaller pixel size the sensitivity of the camera is reduced and this affects the overall inspection capability. Additionally, smaller pixels also require high powered external lighting to compensate for its lower camera sensitivity.



### Working Distance and Object Size



When the field of view of the object to be inspected is large, then the working distance from the camera to the object is also large. This is because larger objects require larger magnification for the same focal length. When the distance between the object and the camera is large a separate gantry or special mounting system might be needed to mount the camera with respect to the object. Additionally this also necessitates free space between the camera and the object. Hence inspection of wide objects in tight installation spaces becomes difficult and would require multiple cameras to inspect the wider object.



### Distortion, Lens Errors and Focus



Another main problem with circular lens optics is the distortion and lens errors. The lens aberrations and distortions can cause the image to appear larger or smaller at different radial locations of the lens. The errors are especially noticeable with smaller focal lengths. However, using larger focal lengths would also result in larger working distance and might not be possible for all installations.



The lens errors are sometimes compensated by software with calibration. However without a proper optical design and installation, the use of circular optics with line scan cameras can create errors in gauging and measurement applications.



## How does the Roll-2-Roll® Sensor compare to a line scan camera



[Roll-2-Roll® Sensor](https://r2r.tech/products/roll-2-rollr-sensor) actually has a line scan camera with pixel counts ranging from 768 pixels ([WPS 48](https://r2r.tech/products/sensors/wps-48)(https://r2r.tech/products/wps-48)) to 14,336 pixels ([WPS 900](https://r2r.tech/products/sensors/wps-900)(https://r2r.tech/products/wps-900)). The main difference is in the optics; instead of circular lens optics Roll-2-Roll® Sensors use linear optics.



The [optical fiber properties](https://r2r.tech/articles/fiber-optic-web-edge-sensor) enable them to act as a lens that can capture light or focus an image onto the imaging element or a pixel. By adjusting the refractive index of the fibers the optical lens can be appropriately designed for image magnification. In principle multiple fibers can be arranged in a tightly packed linear array where each fiber can collect and focus light onto a single pixel as shown below. The fibers can also be staggered on multiple rows to allow a continuous image.

 ![A Concept Working Principle of Roll-2-Roll Sensor](https://r2r.tech/sites/default/files/inline-images/R2RLine-Scan-Sensor-Illusration-01.png)

## Advantages of linear lens optics for line scan cameras



### Larger Pixel Size for Higher Light Sensitivity



By proper design of the refractive index of each individual lens element the linear optical array can provide an image with 1x magnification without image inversion. With 1:1 image transfer the pixel sizes can be as large as the minimum feature size of the object to be detected. In fact, a pixel can be an individual photo diode or an avalanche detector if needed by the application. For most applications, the linear optics focuses the image onto off-shelf pixel arrays with pixel sizes in the range of 63.5 µm x 63.5 µm (400 DPI) or 127 µm x 127 µm (200 DPI). These pixels are significantly larger than conventional line scan camera sensors providing over 100 times more light sensitivity. This significantly reduces the need for special high intensity lighting while having the ability to detect small contrast changes in the image.



### Closer Working Distance and Compact Overall Installation



With 1x magnification afforded by the linear lens optics, the object and its corresponding image captured on the camera sensor are of the same size. So if an image of 900 mm wide needs to be captured then the camera is also 900 mm wide. The WPS 900 is such a camera with over 14,000 pixels and having an image capture range of 900 mm. With 1x magnification the working distance essentially equals the focal length of the lens. And with the focal lengths being fixed, it can be designed to be a lot smaller than with a circular lens. In fact for most of our sensors the working distance is 15 mm or less. Closer working distance also enables us to integrate the lighting with the camera. Overall requiring much less space for installation. This enables integration of the Roll-2-Roll® Sensors in tight working spaces.



### Reduction of Lens Errors and Telecentric View



The linear lens because of its optical properties do not have issues with aberrations and distortion. Hence the image magnification is fixed at any point along the length of the lens. The reduction of errors enables high precision measurements without optical lens distortion. Effectively the linear lens optics behave as [telecentric lenses](https://en.wikipedia.org/wiki/Telecentric_lens), when the object is at the focal length, albeit being inexpensive compared to typical circular telecentric lens.



## Conclusion



In conclusion, [Roll-2-Roll® Sensors](https://r2r.tech/products/sensors) bring the benefit of line scan cameras along with the benefit of linear lens optics to enable a system that is affordable, compact, highly accurate and simple to use. For certain applications they are a viable cost effective alternative to traditional vision systems with 2D or line scan cameras. If you want to add simple inspection capabilities to your process [Roll-2-Roll® Sensors](https://r2r.tech/products/sensors) can help with your application needs. Please [contact us](https://r2r.tech/contact) to know more about how we can help.

---

# Where does the Roll-2-Roll Sensor Technology Excel?

URL: https://r2r.tech/blog/where-does-roll-2-roll-sensor-technology-excel.md

In the last few blog posts we saw how [Roll-2-Roll® Sensor](https://r2r.tech/products/sensors) [compares to common sensors](https://r2r.tech/blog/roll-2-rollr-sensor-just-sensor), to [vision systems](https://r2r.tech/blog/roll-2-roll-sensor-vs-vision-system) and specifically to [line scan camera based vision systems](https://r2r.tech/blog/line-scan-camera-vs-roll-2-roll-sensor). We saw that the Roll-2-Roll® Sensor system is an intelligent embedded sensor with vision capabilities. Unlike typical sensors (such as analog web edge sensors), the vision capabilities enable our sensor to have spatial awareness. This spatial awareness adds intelligence, enabling some unique capabilities for the sensor. In this blog post we will dig deeper into what are the applications that are best suited for the Roll-2-Roll® Sensor.



### For Challenging Materials

 ![WPS 48 Sensor with a mesh web](https://r2r.tech/sites/default/files/inline-images/WebPositionSensorwithLightMesh-WPS48IR.jpg)

One of the first applications of our sensor technology is in [web guiding](https://r2r.tech/articles/web-guiding-system-why-what-where-and-how) where the sensor is used as the feedback device to provide web edge position measurements for a web guiding system. Because of the [spatial awareness](https://r2r.tech/articles/web-position-sensor-overview) the sensor was best suited for detecting challenging materials with varying porosity and opacity. For example, the web position of a mesh or a porous web (that cannot be detected accurately with a conventional sensor) can be accurately measured with Roll-2-Roll® Sensors without any need for time consuming calibration. This reduces waste, downtime and setup time when compared to other competing sensors in the market.



### For High Accuracy Measurement and Guiding Applications



[As seen in the previous blog post](https://r2r.tech/blog/line-scan-camera-vs-roll-2-roll-sensor), the linear fiber optics enable capture of images without lens error. This enables high resolution, high accuracy measurement even with a wide sensor range. For example, the [WPS 900](https://r2r.tech/products/sensors/wps-900)(https://r2r.tech/products/wps-900) sensor has a measurement range of over 35 inches while having the ability to provide a resolution of 0.0025 in. That is about 14,000 discrete positions measurement over the entire sensor range.



[Web width measurement](https://r2r.tech/applications/web-width-measurement-and-monitoring) is one of the most common applications for the [Roll-2-Roll® Sensor](https://r2r.tech/products/sensors) that is enabled by the high accuracy, high precision measurement over a wide range. Forming machines such as blown film lines and extrusion lines are common places where web width measurement and monitoring is needed. Converting operations such as web folding, shrink sleeve manufacturing and slitting are common places for web width measurement and monitoring. Up to 70 inches of web width variations can be measured at a resolution of 0.005” with Roll-2-Roll® Sensors.



The second key application is [web guiding](https://r2r.tech/articles/web-guiding-system-why-what-where-and-how) in machines that process materials with varying web width. A wide sensor allows the user to change web widths without the need to move the sensor (manually or automatically). This unnecessary sensor repositioning is a common source of operator error and downtime in those machines. A wide variety of forming and converting lines run different web widths within the same machine and they all benefit from a high accuracy wide sensor.



### For Contrast or Registration Mark Detection



Apart from web edge detection of challenging materials, the Roll-2-Roll® Sensor system is also well suited for detecting contrasting features on the web. Line guiding or contrast guiding is a key application for contrast detection. One of the unique value propositions of our sensor is its ability to have a wide sensor range. There are no other sensors in the market for line or contrast guiding that is wider than our smallest sensor, [WPS 48](https://r2r.tech/products/sensors/wps-48)(https://r2r.tech/products/wps-48). All of our sensors including the [WPS 900](https://r2r.tech/products/sensors/wps-900)(https://r2r.tech/products/wps-900) can be used for line guiding or contrast guiding applications.



Again the wide sensor range is a key value proposition for registration mark detection and spray ink mark detection applications. Most registration sensors or mark detections sensors have a very narrow field of view, about 2 to 8 mm. The measurement is often plagued by web movement which moves the registration mark away from the field of view of the sensor. To avoid missing the mark, the sensor is installed to chase the web edge so that the mark is never missed. This increases the complexity and cost of the system. Roll-2-Roll® Sensor on the other hand can provide a wide sensor range of 48 mm which can accommodate typically web movement/wander observed in converting lines. With a processing speed of up to 750 Hz or 1.33 milliseconds per image a wide variety of applications benefits from the Roll-2-Roll® Sensor.



### For Simple Inspection Applications



Apart from edge and contrast position detection the Roll-2-Roll® Sensor system is also used for simple inspections applications. These applications include flag detection, tear detection, multiple strip width detection, multiple strip gap monitoring, thread/string detection and counting. These are applications where camera based vision systems might be an overkill while a traditional sensor based solution would be impossible.



### Conclusion



Roll-2-Roll® Sensor does not provide enough value for some simple applications where the accuracy of measurement is not critical. However, there are some unique value propositions of the Roll-2-Roll® Sensor for the following applications:



- Edge detection and measurement of challenging materials
- High accuracy web width measurement
- Web guiding with wide sensors that eliminate the need for sensor repositioning
- Wide range contrast and line guiding
- Wide range registration and spray ink mark detection
- Flag detection
- Tear detection
- Multiple strip width measurement
- Multiple strip gap monitoring
- Thread/string detection and counting



In the future posts we will cover some of these applications in more detail specifically focusing on ease of use, the problems that they solve and cost savings provided. If any of the above applications are relevant to your operations please contact us to see if our solution would provide the best value for you.

---

# Why is WPS being replaced by ODC? And what does it mean to existing customers?

URL: https://r2r.tech/blog/why-wps-being-replaced-odc-and-what-does-it-mean-existing-customers.md

Couple of weeks ago we made an [announcement](https://r2r.tech/articles/roll-2-roll-technologies-llc-announces-new-camera-technology-web-detection) about our new Roll-2-Roll® Sensor product line ODC. We also announced the transition plan for existing customers using WPS to eventually transition to ODC. This caused some confusion and in this blog  we will address this.



## Background



Roll-2-Roll® Sensor WPS has been our flagship product with a lot of success in the industry. Even though we call WPS a sensor, [it is in fact a line scan camera](https://r2r.tech/blog/roll-2-rollr-sensor-just-sensor). We were able to scale the sensor from 16 mm sensing range all the way up to 900 mm; scaling has often been an issue with other sensors on the market. This wide sensing range has been the reason for our success. Unlike many existing traditional sensors, the resolution of the WPS is not affected by the sensing range which has been a significant value proposition for our customers. Long story short, the WPS has been our bread and butter.



We use off-the-shelf camera modules within the WPS and this is just one part of our sensor technology, It is in fact not proprietary. Our key intellectual property has been the [fiber optic technology](https://r2r.tech/articles/new-web-edge-sensor-guiding-applications), which in essence uses any 1D camera module. The second key intellectual property for us is the underlying image processing algorithm. Both of these are the main reasons for our success with the WPS product line, especially with our ability to scale the sensor from 16 mm to 900 mm while providing exceptional [resolution, precision, linearity and accuracy](https://r2r.tech/articles/accuracy-precision-linearity-and-resolution-web-guiding-understanding-terminology).



## ODC Development



As part of our normal R&D cycle, we have been evaluating new technologies for the underlying 1D camera. This started in late 2019 when we picked a new camera module as a supplement for the existing camera on the WPS product line. The new camera uses advanced CMOS technology with some added benefits. The intent of the development was to provide another option to WPS for high sensitivity and high dynamic range applications for simple inspection applications. It was never the intention to completely eliminate the WPS product line. In fact the WPS 1D camera was a cost effective solution for us compared to the newer ODC camera.



## Unintended Consequences of the COVID-19 Pandemic



The camera module used in WPS is made by a large multinational sensor company that supplies parts to high volume customers in consumer electronics and automotive industries. Their initial release of this 1D camera module to the market was in 2016 and before the pandemic this part was supposed to have a long life with no near term availability issues. However, things dramatically changed with the pandemic since this module was also used in the automotive industry. The first sign of distress was seen when the lead time of the part went from 4 weeks to 52 weeks. The writing was on the wall for us to act quickly to get ahead of any potential issue. This accelerated our product development efforts to get the ODC to the market as soon as possible. Our intent was to have an alternative for the WPS if and when we ran out of the camera modules due to long lead times and supply chain issues. Fortunately, we acted on time and our preemptive efforts to get ahead of the supply chain issues paid dividends. To our dismay, just a few months ago we learned that the 1D camera module used in the WPS product line will no longer be manufactured. Late this summer, the manufacturer provided a last buy notice without any prior indication of the end of life (EOL).



## The Transition Plan



The good news is that we were prepared and were able to address the EOL notice with a smooth transition plan for our customers who are currently using WPS sensors.



- First, any customer looking to purchase a WPS would be able to make a purchase until the end of 2022. This is for any new and replacement sensors in existing applications. However, we recommend ODC for any new applications.
- Beginning 2023, customers can no longer purchase any new WPS for any new projects/applications. However, if our customers have already purchased a sensor before 2022 and they need repair/replacement we will provide that support for those customers until the end of 2025.
- Anytime from now onwards, any customer that has purchased WPS from us can upgrade the firmware on their controller so that the controller can work with both the WPS and ODC. With an approved RMA we will provide the firmware upgrade free of charge for the customers until the end of 2025.
- The ODC sensor is designed to be a functional drop-in replacement to WPS. Any purchases made in October 2021 onwards will ship with a firmware that would work with both WPS and ODC sensors. Even if the order is for a system with WPS, these controllers will have the ability to work with the ODC sensors. Essentially, future proofing them in case they want to transition to an ODC from a WPS.



We have tried our level best to provide the smoothest transition plan as possible. By providing at least four years of notice for this transition, we hope that our customers will be able to have a smooth transition. In the following I will specifically address the similarities and differences with the WPS and ODC product line.



## What are the similarities between WPS and ODC?



As mentioned before the underlying sensing technology (fiber optic sensing) is the same for both products. Similarly the image processing algorithm is the same as well. The pixel resolution is also exactly the same with 0.0635 mm and 0.127 mm as the options available. Both sensors use the same cable (M12 12-pin shielded male/female) and can be connected to SCU5 (with firmware update). In fact, we use the same extrusion profile for both ODC and WPS sensors so the sensor installation recommendations are the same as well. We also use the same LEDs for lighting and the power requirement is also very similar.



## What are the differences between WPS and ODC?



Obviously, the main difference is the underlying 1D camera. However, this is a difference that most end users would not see as a difference in terms of functionally. The two main differences that could affect our existing customers are:



- Need for firmware upgrade with existing SCU5 controllers
- Measurement ranges available with the ODC



The need for the firmware upgrade for existing SCU5 controllers is because of the fact that the image capture timing with the camera used in ODC is slightly different from the camera used in WPS. Hence there is a need for the firmware upgrade. The camera inside ODC also has a different sensor measurement range compared to the camera module used in WPS. Here are the comparable ranges for the existing WPS products:



| WPS 48: 48 mm sensor measurement range | ODC 48: 48 mm sensor measurement range |
| -------------------------------------- | -------------------------------------- |
| WPS 112: 112 mm sensor measurement range | ODC 96: 96 mm sensor measurement range |
| WPS 221: 221 mm sensor measurement range | ODC 192: 192 mm sensor measurement range |
| WPS 440: 440 mm sensor measurement range | ODC 384: 384 mm sensor measurement range |
| WPS 900: 900 mm sensor measurement range | ODC 768: 768 mm sensor measurement range |



Apart from the change in the measurement range, this change in physical size will affect customers who are looking for a drop-in physical replacement. Unfortunately, we were unable to match the physical dimensions exactly since that would have made the overall sensor significantly cost prohibitive. This is because of the unnecessary overlaps between different camera modules that are needed to exactly match the dimensions of the WPS products.



## What's new with the ODC?



The underlying camera technology is much more advanced than the one in WPS. The camera module has a new and improved CMOS technology that is highly sensitive to the smallest of light changes. This means that the sensor can detect hard to sense materials and low contrast differences much better than the WPS. This also means that only a low amount of light is needed to sense materials and hence would have a lower overall power consumption compared to WPS. The CMOS technology also uses global shutter for image capture and this will eliminate motion blur, especially with a wider sensor range. All of these are positioning them to be well suited for simple inspection applications apart from the traditional edge position measurement applications. The dynamic range of the image captured can also be increased by 8x when the ODC is combined with the soon to be released (by end of Q1 2022) SCU6. And finally the ODC can achieve 4x the scan rate compared to the WPS for certain custom applications.



And more importantly the ODC can be used with existing controller, cables, etc., with the latest v3.6 firmware that has started to ship since October 2021.



Hopefully this blog post provides some context on why we had to make that change, what the transition plan is and how customers can be prepared to make this transition as smooth as possible. More blog posts will follow with more information. Our company’s key differentiation, apart from industry leading technology, is our uber responsive support. So if you have any questions please feel free to give us a [call or email us](https://r2r.tech/contact). We are here to help you.

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# Why We Use Stepper Motors for High-Thrust Web Guiding Actuators

URL: https://r2r.tech/blog/stepper-motors-high-thrust-web-guiding.md

*An engineer-to-engineer look at the design choices behind our high-thrust linear actuators, including the tradeoffs we accept and the ones we don't.*

## The Default Assumption — and Why It Deserves Scrutiny



Ask any motion control engineer to spec a high-force, precision linear actuator for an industrial web guiding application and they will almost reflexively reach for a servo motor. The arguments seem compelling: closed-loop position control, smooth torque across the speed range, high bandwidth, clean direction reversals. Stepper motors, by contrast, carry a reputation as "open-loop" devices prone to step loss, resonance, and thermal issues — fine for light-duty positioning, unsuitable for serious industrial work.



That reputation is not unfounded. Steppers do have real limitations, and we will address them directly in this article. But after years of building and deploying high-thrust linear actuators in web guiding applications — moving loads up to 30,000 lb on precision linear bearings — we have found that the specific demands of web guiding change the motor selection calculus in ways that are worth examining carefully.



This is not an argument that steppers are universally better than servos. It is an explanation of why, for this particular application profile, we chose steppers and continue to stand behind that choice.



---


## Understanding What Web Guiding Actually Demands



Before selecting a motor technology, you need to characterize the application honestly. Web guiding is not a general-purpose positioning problem. It has a specific operating profile that shifts the engineering tradeoffs significantly:



**Correction bandwidth is very low.** In most web guiding applications, the web edge wanders at 0.5 to 2 Hz. This is extremely slow in motion control terms. The high-bandwidth torque loop arguments that favor servo motors — current loop rates of 1-5 kHz, rapid direction reversal response — are simply not being exercised at these correction rates. Nearly any motor technology can track a 2 Hz correction signal without issue.



**A deadband is standard practice.** Rather than continuously driving the error to zero, most web guiding controllers use a deadband — a tolerance window within which no correction fires. This means the motor is at rest the vast majority of the time, making discrete low-speed moves followed by a return to standstill. Instead of continuous reversals through mid-speed ranges, you have occasional discrete moves separated by dwell periods.



**The outer loop closes on the web, not the motor.** The position feedback in a web guiding system comes from a [Roll-2-Roll® Sensor](https://r2r.tech/products/sensors) — a fiber-optic array, camera, or ultrasonic sensor reading the actual web position. This sensor closes the loop over the entire drivetrain: motor, coupling, ballscrew or roller screw, and any mechanical compliance in the system. It corrects for everything downstream, including any positional imprecision from the motor itself.



These three characteristics — low bandwidth, deadband operation, and web-sensor outer loop — collectively transform the motor selection problem. It shifts from a high-performance tracking challenge to a reliable, consistent actuation challenge. The motor needs to be a dependable, low-hysteresis device that moves predictably when commanded. The web sensor handles the rest.



This analysis is not controversial. Any controls engineer examining the transfer function requirements would reach similar conclusions. Where things get more interesting is what happens when you follow these requirements through to the motor selection decision.



---


## Where Servos Earn Their Premium — and Where They Don't



We want to be clear about something: servo motors are excellent. In applications with high closed-loop bandwidth requirements, continuous operation through frequent direction reversals at speed, or where the motor is the primary position feedback element, servos earn their premium many times over. We are not arguing against servos in general.



What we are arguing is that when each of those conditions is absent — as in low-bandwidth, deadband-controlled, web-sensor-corrected applications — the servo advantage narrows to the point where other factors dominate the selection.



**Low bandwidth reduces the dynamic performance argument.** The servo's ability to execute clean, high-speed direction reversals with minimal settling time matters less when your correction loop is running at 0.5 Hz. A conservatively tuned servo and a well-sized stepper both execute a slow correction move adequately. The servo's edge at higher speeds and bandwidths is real — it simply is not being exercised.



**The deadband reduces resonance excitation.** Stepper motors have a well-documented mechanical resonance, typically in the 50-200 Hz range. We address resonance mitigation in detail below because it is a legitimate concern. But the deadband operation profile helps: you are not executing continuous oscillatory motion through resonant speed bands. You are making discrete, low-speed moves separated by dwell periods. This does not eliminate the resonance concern — it reduces how often the motor operates in conditions where resonance is most problematic.



**The outer loop changes the step-loss equation.** The standard objection to open-loop steppers is that a lost step is invisible and creates a permanent position error. In a web-sensor-closed-loop system, the sensor detects the resulting position error and corrects it on the next cycle. Step loss becomes a recoverable event rather than a silent fault. This does not mean step loss is acceptable — it means the system can tolerate occasional step loss without catastrophic consequences, which changes the required reliability margin from "never" to "extremely rare."



---


## The Honest Tradeoffs: What We Give Up with Steppers



Before explaining why we still chose steppers, we owe you a straightforward accounting of what we gave up. Engineers trust sources that acknowledge limitations, and these are real.



### Energy Efficiency



Stepper motors are less energy-efficient than servos. A servo draws current proportional to load — near-zero current at standstill under no load. A stepper draws its programmed hold current at standstill regardless of load. In continuous-duty, high-speed applications, this difference is significant.



In web guiding, it matters less than you might expect. The duty cycle is dominated by standstill dwell time within the deadband, with brief low-speed correction moves. Our intelligent microstepping drivers mitigate standstill losses through automatic hold current reduction — programmable down to 50% of run current after a configurable delay — and adaptive current control during motion that scales motor current to actual load demand. We typically see total power consumption in the range of 6.5 W to 210 W depending on actuator model. But we are not going to claim parity with servos on efficiency. Servos win this one.



### Audible Noise



Steppers are louder than servos. The discrete stepping action, even with 256-microstep interpolation, produces audible noise that servo motors do not. Voltage-mode PWM — a silent operation mode designed for low-velocity, low-noise operation — significantly reduces this noise at the low speeds typical in web guiding. At walking pace and below, stepper motors driven in this mode are genuinely quiet. But at higher speeds or during acceleration, a stepper will be more audible than a comparable servo. In most web guiding installations — industrial environments with significant ambient noise — this is not a practical concern. In a quiet laboratory or cleanroom, it might be.



### Speed Limitations



Stepper motor torque falls off with speed. This is fundamental to the technology — the back-EMF at high speed reduces available current, and torque drops. Our actuators are rated up to 2 in/sec (51 mm/sec), which is adequate for web guiding correction moves but would be limiting in applications requiring fast, long-stroke repositioning. Servos maintain much flatter torque-speed curves and can deliver rated torque at significantly higher speeds.



For web guiding, the speed limitation is not constraining. Correction moves are short-stroke (typically under 0.5 in / 12 mm per correction cycle) and low-speed. But if your application requires fast homing, rapid retract, or long-stroke positioning at speed, a servo has a genuine advantage.



### Thermal Dissipation at Standstill



Steppers draw current when holding position, which means they generate heat at standstill. This is the opposite of a servo, which draws near-zero current when stationary under no load. For web guiding, where the motor spends most of its time in the deadband at standstill, this seems like it should be a significant concern.



In practice, we manage this through the driver's current management features. Hold current is automatically reduced after a programmable delay following the last step — typically to 50% of run current. Adaptive current control further reduces current during low-load motion. The result is that thermal rise at standstill is modest and well within motor ratings. We have not experienced thermal failures in field installations. But the heat is there, and in a thermally constrained enclosure, it needs to be accounted for in the system thermal budget. We will not pretend otherwise.



---


## The OEM Shipping Problem: Why We Chose Steppers Despite the Tradeoffs



With all those limitations acknowledged, here is the engineering argument that tipped our decision — and it is a practical one more than a theoretical one.



Roll-2-Roll Technologies manufactures actuators and ships them to end users for field installation. We do not commission every installation ourselves. Our customers — converters, paper mills, film extruders, battery manufacturers — install these actuators on their own equipment, often with millwrights and electricians who are skilled at mechanical and electrical installation but are not motion control engineers.



Servo motors carry a commissioning cost that rarely appears in component-level engineering comparisons: tuning.



Servo tuning is fundamentally a load-dependent process. The gain parameters that determine stability and response — the inertia ratio, friction characterization, and mechanical resonance frequencies — are all properties of the installed machine, not the actuator in isolation. A servo drive tuned on the manufacturer's bench without the actual load is tuned for the wrong system.



Modern servo drives offer auto-tuning features — Yaskawa's Sigma-7 "Tuning-less" mode, Kollmorgen's AKD2 inertia identification wizard, and others. Integrated servos like the Teknic ClearPath and Applied Motion StepSERVO have made real progress in closing the complexity gap, and we acknowledge that the servo commissioning experience is significantly better today than it was a decade ago. But auto-tuning still requires the load to be connected and the machine to execute test motions. It transfers the tuning process from the factory to the field. It simplifies it — genuinely — but it does not eliminate it.



**Here is what we want to be precise about:** with a stepper motor and an intelligent microstepping driver, the *motor drive* requires no field tuning. Run current, hold current, microstep resolution, and acceleration ramp are set at the factory. These parameters are not load-dependent in the sense that they need to be re-optimized per installation. Size the motor for worst-case load with adequate margin, set conservative acceleration profiles, and the drive is ready to ship.



This does not mean the *system* requires no tuning. The web guiding controller itself — whether ours or a third party's — still requires configuration: PID gains, deadband width, sensor filtering, guide response aggressiveness. That tuning is application-specific and unavoidable regardless of motor technology. What the stepper eliminates is one commissioning step: the motor drive tuning that interacts with mechanical load dynamics. One fewer thing for a field technician to get wrong, one fewer support call.



That distinction matters for an OEM shipping hundreds of actuators per year. It does not make steppers universally superior. It makes them a better fit for our specific business model and deployment context.



---


## The Load Capacity Question: Putting Real Numbers on It



One common concern about steppers in high-thrust applications is torque capacity. Servo motors offer more continuous torque at equivalent frame sizes due to better thermal characteristics. This is true, and we do not dispute it.



What we can share is our field experience: our RLA-series actuators, using stepper motors rated at 5.5-7 A RMS, have guided loads up to 30,000 lb on precision linear rail bearings across hundreds of installations with multi-year service records, without step loss or reliability issues.



**The critical nuance that the "30,000 lb" number requires:** this is the total load weight resting on precision linear bearings, not the thrust force the actuator must produce. Precision linear rail bearings (recirculating ball or roller type) have a rolling friction coefficient of approximately 0.003-0.005. The actual force required to move a 30,000 lb (13,600 kg) load on these bearings is:



- Friction force: 13,600 kg x 9.81 m/s² x 0.004 = ~533 N (~120 lbf)
- Add acceleration force for a typical 50 mm/s² ramp: 13,600 kg x 0.05 m/s² = 680 N (~153 lbf)
- Total peak thrust requirement: ~1,213 N (~273 lbf) before safety factor
- With a 2x factor of safety: ~2,426 N (~546 lbf)



Our RLA actuators produce 500-2,000 lbf (2,224-8,896 N) of thrust, putting the motor well within its operating envelope with substantial margin. The motor is typically operating at 30-50% of its pull-out torque under these worst-case conditions. At that operating point, step loss does not occur.



The correct engineering process is sizing verification at design time — calculate worst-case static friction breakaway force (accounting for cold start, contamination, and bearing wear increasing friction coefficient over time), acceleration torque for the load inertia, and any web tension reaction forces, then size the motor so that the required torque is well below the rated pull-out torque under all conditions. We recommend a minimum factor of safety of 2.0. This is a design calculation done once, not a per-installation procedure.



---


## Addressing Resonance Honestly



Stepper motor resonance is real and cannot be dismissed. The rotor-stator magnetic coupling creates a second-order mechanical system with natural resonance typically in the 50-200 Hz range. When a stepper is driven through these frequencies, vibration, noise, and potential step loss can occur. This is a well-documented characteristic, not an edge case.



We do not claim resonance disappears. What we can describe is how current-generation intelligent microstepping drivers provide multiple mitigation layers, and why the web guiding duty cycle reduces exposure:



**Voltage-mode PWM (silent operation mode).** At low velocities — which is the primary operating regime for web guiding correction moves — the driver uses a voltage-mode PWM scheme. Unlike current-chopping drivers that produce discrete current steps with sharp edges (which excite mechanical resonance), this mode produces smooth, sinusoidal current waveforms. The result is significantly reduced resonance excitation during the low-speed moves that dominate web guiding operation.



**Cycle-by-cycle current control.** For faster moves — during homing or long-stroke repositioning — the driver transitions to a cycle-by-cycle current regulation mode with active resonance damping. This mode measures actual motor current on each PWM cycle and adjusts to maintain the target, which damps oscillations that would otherwise build up at resonant frequencies.



**256-microstep interpolation.** The driver interpolates to 256 microsteps per full step, subdividing each step transition into much smaller increments. This reduces the energy impulse at each step transition, which in turn reduces the energy available to excite resonance. The motor moves more smoothly through the resonant speed band rather than being kicked through it in large discrete steps.



**Configurable acceleration ramps.** The driver supports S-curve and linear acceleration profiles that can be configured to minimize dwell time in resonant speed bands. By accelerating through the resonant range quickly rather than dwelling in it, resonance amplitude is limited.



**Deadband operation profile.** Because web guiding uses a deadband, the motor is not continuously oscillating. It makes a correction move, stops, and dwells. This intermittent operation reduces the opportunity for resonance to build to problematic amplitudes. It does not eliminate the concern during the move itself, but it limits cumulative exposure.



Taken together, these mitigations make resonance manageable in web guiding. We have not experienced resonance-related step loss in our field installations. But we want to be clear: in applications requiring continuous high-speed oscillation through the resonant range, steppers remain problematic, and servos are the right choice. Web guiding's duty cycle avoids the worst case.



---


## Sensorless Stall Detection: A Useful Fault Detection Layer, Not a Complete Solution



Our intelligent microstepping drivers include a sensorless stall detection feature that monitors the back-EMF signature of the motor during motion. As load increases and the rotor begins to lag the stator field, the back-EMF waveform changes in a measurable way. The driver reports a continuous load value that decreases toward zero as the motor approaches stall, and you can set a threshold for early-warning detection — before steps are actually lost.



We use this as a fault detection mechanism: identifying abnormal conditions like a jammed guide, a seized bearing, or a mechanical obstruction before they become failures. In this role, it is effective and valuable.



**But sensorless stall detection has real limitations that deserve acknowledgment:**



- It cannot detect partial step loss. If the motor loses a single step or a small number of steps but continues running, the detection may not flag this. It detects gross load increases approaching stall, not subtle position drift.
- It has reduced sensitivity at very low speeds. Back-EMF amplitude is proportional to speed, so at the very low speeds typical in web guiding, the signal-to-noise ratio decreases. Threshold calibration at the actual operating speed is essential, and there is a minimum speed below which the detection is not reliable.
- It is not a substitute for an encoder in applications where absolute position accuracy from the motor is required.



For web guiding, these limitations are acceptable because stall detection is not the primary feedback mechanism — the web sensor is. It serves as one layer in a multi-layer protection strategy:



1. Torque margin — the motor is sized with sufficient margin that step loss is extremely unlikely under normal operating conditions
2. Web sensor outer loop — any position error from occasional step loss is detected and corrected on the next sensor cycle
3. Sensorless stall detection — detects gross mechanical faults (jams, obstructions, bearing seizure) before they cause damage
4. Limit switches — hardware travel limits as a final safety net



No single layer is relied upon as a complete solution. The combination provides robust protection without the added cost, cabling, and potential failure mode of a motor-shaft encoder — which, in this application, would be telling you where the motor is rather than where the web is.



---


## The Narrowing Servo Advantage — and Why It Still Matters



We would be doing you a disservice if we pretended that the servo landscape is the same as it was ten years ago. It is not.



Integrated servo motors like the Teknic ClearPath and Applied Motion StepSERVO have significantly reduced the cost and commissioning complexity that historically separated servos from steppers. These products combine motor, drive, and encoder in a single package with simplified setup workflows. The ClearPath in particular has earned a strong reputation for making servo performance accessible without deep motion control expertise.



The cost gap has narrowed. The commissioning gap has narrowed. For a new design starting from a clean sheet, the decision between a modern integrated servo and a stepper with an intelligent driver is closer than it has ever been.



We believe the stepper still holds an advantage for our specific use case — an OEM shipping actuators for field installation in web guiding systems with an outer web-sensor loop — for these reasons:



- No field tuning of the motor drive whatsoever. Even simplified servo auto-tuning requires load connection and test motions. Our stepper drives ship configured.
- No encoder to fail or require alignment. One fewer component, one fewer cable, one fewer failure mode in a dirty industrial environment.
- Native holding torque without servo dither or power consumption. The stepper holds position magnetically at standstill. A servo must actively servo to maintain position, even if the current is small.
- Cost advantage at the system level. Even as component costs converge, the elimination of encoder hardware and field commissioning time maintains a total cost of ownership advantage.



But these advantages are specific to the OEM shipping model and the web guiding application profile. If you are building a one-off machine, commissioning it yourself, and need higher speed or continuous duty — evaluate those integrated servos seriously. They are good products solving real problems.



---


## Where the Mechanical Selection Still Matters



Choosing a stepper over a servo does not reduce the importance of mechanical design. For high-thrust web guiding with loads in the 10,000-30,000 lb range, the mechanical drivetrain is arguably more critical than the motor technology choice.



**Ballscrew vs. roller screw selection.** At high loads with frequent start-stop cycling, ball screws fatigue the ball track over time. Planetary roller screws distribute contact stress across many more contact lines and offer dramatically longer service life under these conditions. Our RLA series uses ball screws and roller screws depending on the load and duty cycle requirements. Vendors like Exlar (now Curtiss-Wright) and Tolomatic who design integrated roller screw actuators for servo motors are applying the right mechanical technology — the value of a properly designed screw actuator is independent of whether the motor is a servo or a stepper.



**Backlash and preload.** Any mechanical backlash in the drivetrain adds dead zone to the correction response — the actuator moves but the load does not until the backlash is taken up, causing the web sensor control loop to over-command before motion begins. A properly preloaded ballscrew or roller screw, combined with appropriate coupling from motor to screw, controls this effect.



**Breakaway consistency.** At very high loads on linear rails, static friction at breakaway can be variable — affected by lubrication condition, temperature, contamination, and load distribution. Inconsistent breakaway means the first increment of each correction move is unpredictable, which the outer control loop must then correct. Well-maintained, properly lubricated bearing systems with consistent preload minimize this variability and are worth engineering attention regardless of motor technology.



---


## The Complete Architecture



For a high-thrust web guiding application, the architecture we have converged on after years of field experience is:



- Motor: Properly sized stepper motor with at least 2x torque margin over worst-case load conditions (accounting for bearing wear, contamination, and cold start friction), driven by an intelligent microstepping driver
- Driver configuration: Voltage-mode PWM for low-speed correction moves (smooth, quiet, resonance-reduced), with automatic transition to cycle-by-cycle current control for faster homing/repositioning. Hold current reduced to 50% after dwell timeout. 256-microstep interpolation enabled.
- Fault protection: Sensorless stall detection threshold characterized at factory operating speed and current, configured as a fault-stop condition. Supplemented by hardware limit switches and web sensor edge-loss detection.
- Drivetrain: Preloaded roller screw or ballscrew actuator with minimal backlash, appropriate coupling from motor to screw
- Position feedback: [Roll-2-Roll® Sensor](https://r2r.tech/products/sensors) (fiber-optic, camera, or ultrasonic) closing the position loop at the web, not at the motor shaft
- Control loop: Deadband-controlled correction loop running at 0.5-2 Hz correction bandwidth, with PID gains, deadband width, and sensor filtering tuned per application



This architecture eliminates motor drive field tuning, leverages the stepper's native holding torque and mechanical simplicity, and relies on the web sensor to perform the function that a motor-shaft encoder would otherwise attempt to approximate — which is knowing where the web actually is, not where the motor thinks it is.



It does not eliminate all commissioning. The web guiding controller still needs to be configured for the specific application — gain settings, deadband, response aggressiveness. That work is inherent to web guiding regardless of actuator technology.



---


## When Not to Use This Architecture



Engineering honesty requires identifying where our approach is not the right fit:



- High-speed, continuous-duty applications. If the actuator needs to move at speeds above 2 in/sec (51 mm/sec) for sustained periods, stepper torque falloff becomes limiting. Use a servo.
- Applications without an outer position loop. If the motor must be the primary position feedback device (no web sensor or equivalent), an encoder-based servo or closed-loop stepper is necessary. Our open-loop stepper approach depends on the web sensor closing the position loop.
- Thermally constrained enclosures. If the actuator is enclosed without adequate heat dissipation paths, the stepper's standstill current draw creates thermal challenges that a servo avoids.
- Applications requiring continuous oscillatory motion. If the actuator must oscillate continuously through a wide speed range without a deadband, stepper resonance becomes a more significant concern even with driver mitigation features.
- Single installations where you control commissioning. If you are building one machine, installing it yourself, and have motion control expertise available, the servo's commissioning burden is manageable and you gain efficiency, speed, and continuous-duty thermal advantages. The OEM shipping argument is strongest when multiplied across many installations.



---


## Conclusion



The conventional preference for servo motors in high-performance positioning applications is well-founded — in general. But engineering decisions that are correct in general may not be optimal for a specific application profile.



Web guiding with a low-bandwidth outer sensor loop, a deadband, and the OEM constraint of shipping to field installations without load-specific commissioning is a specific application profile. It is one where the servo's primary advantages — high-bandwidth closed-loop response, smooth torque at all speeds, superior energy efficiency — are either not being exercised or are secondary to the practical benefits of zero motor drive tuning.



We chose stepper motors for our actuators because, in this specific application, the engineering tradeoffs favor them. We give up efficiency, speed, and some noise performance. We gain commissioning simplicity, mechanical simplicity (no encoder), native holding torque, and a total cost of ownership that holds up across hundreds of field installations.



The web sensor does the precision work. The mechanical drivetrain determines the service life. The stepper provides the force. The intelligent microstepping driver manages the stepper's known weaknesses — resonance, heat, and noise — through sophisticated silicon. Each element does what it is best suited for.



That is our engineering rationale. We have tried to present it with the tradeoffs visible, not hidden. If it helps you make a better-informed motor selection decision — whether you choose steppers or servos — then this article has served its purpose.

---

# Advanced Contrast Sensor Capabilities for Slitting Operations

URL: https://r2r.tech/videos/advanced-contrast-sensor-capabilities-slitting-operations.md

Roll-2-Roll Technologies has released a new feature for it's web position sensors. This feature benefits the slitting converter operations. The advanced contrast sensing capabilities can detect the smallest changes in colors and markings. Stay tuned for more information about our advanced contrast sensor capabilities for slitting operations.

## Transcript

So here at Roll-2-Roll Technologies we keep advancing with our developments. Today I want to talk to you about the contrast sensing application and something new that we have come up with through our development space. So we have set up here a screen where we'll show you the contrast being read by the sensor below. In this case I'm going to show you this is a strip of material that has several labels on top of a white substrate and as I present it to the sensor, you will see on the screen how it can actually see each one of those labels and the position of the labels, right.

So this is a silver on white. We can also look at a white on white if necessary and as you can see it actually detects where the material is at. I think you can see the edge of the material and you can see actually the white strip in on that white substrate Another thing is we can actually also look at different colors and it can look at each one of them individually and seen on the screen. More extreme, we have this white on white label so we have a label on extremely white substrate we can hardly see it with our eyes but as you can see not only this would pick up the edge of the material and the edge of that white label on it but if we have a a printed yellow line also and you can also detect the two all at the same time.

Now what this application is one of the applications for this type of feature is for example on slitting applications where previously you would need to print a line on the on the material in order to do the slitting by guiding yourself off the line now you can do it like just guiding the material off this any type of age of a label. It doesn't matter the contrast is very low so all that because our sensor feature that can detect any type of differences in contrast with our powerful sensor application. So you can see more of this Roll-2-Roll Technologies and our website www.r2r-tech.com

---

# Advanced Multiple Web Width Measurement with SCU6x Controller and App Integration

URL: https://r2r.tech/videos/advanced-multiple-web-width-measurement-scu6x-controller-and-app-integration.md

Multiple Web Width Measurement is made simple by the SCU6x Controller and the application that is accessible through Ethernet communication for a continuous multiple web width measurement. This application allows converters with processes such as slitter rewinders to eliminate down time due to width verification of the multiple webs. This unique feature of the Roll-2-Roll Technologies SCu6x Controller allows for monitoring and data collection of up to 32 web widths simultaneously and constantly.

This tutorial from Roll-2-Roll Technologies presents the features of the Ethernet Application for extracting data from the SCU6x controller for multiple slit width measurement applications. Building on a previous video, this episode focuses on setting up and utilizing the new app interface via Ethernet to track the width of multiple webs efficiently. The video guides viewers on configuring controllers, setting nominal widths, and managing alarm and warning limits. It also covers data download options and the benefits of real-time, inline measurement, all facilitated through an easy-to-use app interface. Subscribe and enable notifications to stay updated with the latest advancements in web handling technologies.

00:00 Introduction and Previous Video Recap
00:34 Setting Up the SCU Six X Controller
01:33 Navigating the App Interface
04:49 Configuring Width Measurement Parameters
12:24 Teaching and Calibration Procedures
16:59 Pattern Mode and Advanced Features
19:30 Data Download and Management
26:38 Reopening and Managing Multiple Controllers
28:49 Conclusion and Contact Information

## Transcript

[Music] Hello everyone. This is Arvin Seadri from Rollto-roll Technologies. In the last video, we looked at how to set up the SCU6X controller for multiple webwidth measurement with a single sensor. We're going to continue on that video.

In case you haven't watched that video, go take a look at that and then this will be a continuation of that. In case you haven't subscribed to our channel, please subscribe and follow us and turn on the notification bell. Today we're going to look at how to get the data from our SCU6X controller and specifically the multiple slit width measurement application. In a previous video, we looked at how to set up that application with the SEO 6X controller.

In this video, we're going to look at how to do that from the app we have through the Ethernet interface. Just to recap, we have a sensor here that is ODC960 and we got like five different webs there. So, we're going to track the width of each lane that we have there. And like I mentioned in the previous video, we looked at how to measure and set some of the parameters from the SEO6X controller.

And in this video, we're going to look at how to do the same thing with our app. So if you have the applications where you want to measure the multiple slit width, we would have provided you with an application and you can open that application and get started. So I'm going to start with that. You can doubleclick on the icon and that will open up this interface.

Because we don't have any controller set up the first time, we do have to set that controller for the first time. this dialogue would open and you need to know the IP address of the controller. We have additional videos in our library that shows how to find the IP address of the controller in in case you don't know that. Also, we need to be in the same network where the controller is set up and where the computer is set up.

So, we we have that condition here. So, I'm going to type in the IP address of the device, which is 192.168.1.100. And then that will open up a dashboard. And I'm going to bring it to my screen here.

So, you can see that. So, this is the dashboard that opens up. Few things with with this dashboard. You can see that it's currently showing what sensor we have connected.

Sensor one is ODC 960 with 7,590 pixels. And then it also gives us some information on the thread count. I mean, it's thread count or web count. It's pretty much the same thing.

And it has a dashboard that shows a few different things here. Because we're looking at the width measurement application, we're actually not going to be on this screen. We're going to be on a different screen. to look at all the different options that we have.

You can go into that screen and pretty much pick the menu that you want to choose. Few other things you can label this controller. So you can say it is top mandrel or job A or whatever that is that you want to set it up. Usually in a slitter rewinder you have two rewinds and after slitting it's split into a duplex and then you can have the top and the bottom.

So you can name that like that. The other thing that you can do is you can set the default download folder location top mandrel and then you can select that folder. So anytime we collect the data and we download the data from this app that's going to go into that folder. If you have another controller and another IP address, you can have an independent folder for that also and set that up so that each each one of those controllers have a different place to download that data.

This screen that you see here is going to be exactly the same thing that you're going to see on the SC6X controller. You have the brightness, you have the contrast, and all of those things. If I change any of these parameters, you can see that it's also changing in the SC6X controller. So the brightness is set to five here.

If I change this brightness, that's going to show up on this one, too. So now the brightness is 22. Essentially, it's just a mirror of what we have there. Everything we did with the SCU6X controller can be done through this app in terms of setting the brightness, contrast, or width specification.

I'm going to go to the width config. This is where we spent a lot of time in the previous video on how to set up the samples. Compared to the other screen on the SCSX, this is just one screen. You got everything you need on this screen.

So again, to go through the widths, you can press this icon here, the arrow keys, and it's telling you what web width we have. So width five, and it's allowing us to scroll through there. The computer width is the actual measurement. When I go to the next one, you see different measurements for each of those.

And the raw width is what the sensor is measuring. Then you add that correction and you get the computer width. So that one is also available here on this. So each everyone every single width.

You can see that the correction is changing like we taugh in the previous video. And then each of them has their own sample width. We looked at in the video how to change it in the SC6X controller. In this case, if you want to change it, it's simpler.

You just type in the exact number for that. So I can say 49.35 and it will enter that number. It will enter the value closest to the pixel value in our sensor. It won't be exactly 49.35.

In this case it was 49.3395. Based on the resolution for most cases it should be good enough. If you want to change the upper limit you can do that too. So I can say 1.2 and save.

then it's going to go to the nearest value which is 1.1906. So you can do that for all of these parameters. And we also looked at alarm and warning limits. The same icon when you have warning and alarm you got four parameters that you can enter.

You can say for the warning what are the upper limit and the lower limit and for the alarm what are the upper limit and lower limit. Usually the warning limits are going to be closer to your nominal width and then the alarm ones are going to be farther away from the nominal width. So if you press this icon, you can change between either you want to do alarm or warning or you want to go to a simpler version of upper limit and lower limit just like what we had in the SEU 6X video. And then if you want to set the warning limits, you go on to this icon and press that.

And now it shows you the warning limits there. The warning limits are smaller than the alarm limits. And that's what we are seeing here. It makes it easy for us to switch between that and enter those values.

This one is the units. So you can switch between millimeters or inches right here. For all of these you can again enter those nominal widths and upper limit and lower limit just like we had in the other video. So in order to set up the app for multiple split width measurement application you can go into this width configuration screen.

As you see the width configuration screen is pretty similar. On the top you have the realtime preview of what the sensor is seeing and it's the same as what you have here except that you have all the parameters that you can set for your width measurement application. You got the live preview showing the five webs I have installed up there. You can use this arrow key to navigate from one web to another web and that way you can see the actual measurement for each web in real time.

There are two main things that an operator can do with this particular page. One is to set the nominal width, upper limit, lower limit, alarm, warnings and all those kind of things. So that you can set this up to constantly monitor the multiple widths and provide a feedback whenever something is unusual or outside your tolerance limit. that can be done by setting the nominal width, upper alarm limit, lower alarm limit and warning limits or those kind of things.

If you have watched some of our previous video, you know what I'm talking about in terms of alarm, warning, upper limit and lower limit. There are two types of setups that you can have. One is a simple setup. You have a nominal width, an upper limit, and a lower limit.

As long as the web is between those you get an all good signal. If the web width is more than the upper limit then it will trigger a particular digital output and then if it is below a lower limit it'll create a particular digital output. To set that up you need to be in upper limit lower limit mode and then you can set your values for that. So you can just enter the value.

I can say 1.25 25 for the upper limit 1.25 and then that provides that value. The value is exactly not 1.25 just because of the fact that it is going to round it to the nearest pixel resolution. So in this case it's 1.2383 which is close to 1.25 mm. And then likewise you can set this lower limit.

So I can set this to minus 1.25 mm or to 4 mm and that is going to go to the nearest pixel value with the nominal width and the upper limit and the lower limit. If the web width is right now it's at 49.3354 and if it is more than 1.2 mm from this then you will have the trigger output get triggered for that. So that's the upper limit and lower limit. If you need an extra layer where you want to have a warning and then an alarm, you're going to go into this other mode which is called as the warning/ alarm mode.

And when I click on that, there was another button that showed up here. And this is going to set the warning limits as well as the alarm limits. So the warning is below the alarm limits, much closer to the nominal width. To set that, click on this icon.

I already have some values there. Minus 508 and 492. If the actual width is between these limits, you get an all good signal. If it goes past the upper warning limit or if it goes past the lower warning limit, then a warning trigger would come in.

And then if it goes past the upper alarm limit or goes below the lower alarm limit, another digital output would trigger. Now, we are using Ethernet here, so you don't need those alarms because you're going to be having the data in there. But if you want the operators to know about this, then you have the ability to set these up and do it. So that's the first functionality with this screen.

The second functionality that we have is a teaching and calibration. This is essential whenever you have a width measurement tolerance where you need a tolerance within a millimeter. In those cases, we recommend an additional teaching procedure so that you have these set up as good as you can get. The use case for this is in a typical scenario, a slitter rewinder is set.

Let's say it's an automotive or a pharmaceutical application. The operator sets the slitter blade positions. He or she pulls the web through the machine. They take a sample for each of the liquid and that goes into a QC lab.

Those samples are measured and approved. Once that is approved, then the operator is going to keep running the machine. And then depending upon the the the level of data that the end customer needs, there might be a sample taken every new jumbo roll or randomly. With this setup, the measurement can be taken 100% online and in line and it reduces the time that is needed to keep doing that sampling where the operator needs to stop the machine and then take the sample splice and re-plice and then make sure that they can run the machine.

So, it's a lot of time that is being saved with this type. In order to get the maximum resolution and accuracy, what we do is that when a new job is set up, the operator is going to set the blades, pull the web, and take a sample. And whatever that sample is, we're going to use that and enter that into this app. And from then on, as long as that same pattern is there, you don't ever have to retake a sample because this app would be able to take that data 100% of the time.

So, how to do that? Let's say you have a sample that you pulled and you have the value for the sample. You're going to enter that sample in there and then press enter or save. Just for this case, I'm going to make a small change there.

Let's say 49.4. 425 is actually my sample width. Okay. So that had taken that sample width there.

If you observe this, what that teaching does is that we have a raw width that is 49 and then the sample width is essentially 49.4189. It's pretty close randomly. It just happened that it's pretty close. But then it's going to take that difference between those two and put this in the correction.

So I'm going to have this in teach correction and going to turn off all of these features. And now I'm going to hit the teach button. It says do you want to teach the width correction and confirm it's teaching and it's providing the difference. So right now the correction is 0.0159 essentially 15 micron.

So that's the lowest resolution that we have in our camera. So that's essentially one pixel difference. That's what you're seeing there. So you can do that for every single sample.

And just to make it simple, you can enter all of these samples in different webs. And you can just have this button teach all enabled and then press teach and it's going to teach all the samples at the same time. Then each one of them will have its own correction. So just to show you I'm going to reset all of these.

All the corrections are now zero. Now I can do teach all and then you get all of them a small correction that is being added to every single sample. The use case for this is when you're running a big job, let's say for multiple weeks, the operator sets up the snitter blades, pull the web through, take a sample just like how you would do right now, and then that sample you're going to enter it in there. From then on, as long as that jumbo roll or the slit pattern doesn't change, they can just keep running this material through the slit rewinder.

You can have 100% online inline measurement without needing to stop and take a sample. That's the advantage. One of the other things we have is what we call a pattern mode. This mode provides an additional level of confidence for the measurement.

When you have a particular pattern of slitting that is done with the top and the bottom, you can turn on the pattern teaching mode and then you can press this button and say teach pattern. And what it's going to do is it's going to not only record the widths but also record the edge positions for each of these. So it will keep track of the width change as well as an edge position change for that particular pattern. And then when I say confirm, once this is confirmed, this will automatically turn green.

One thing that happens with this is that if I introduced another material in there, you can see that it that web in between is being disregarded. It still says that my fifth web is the last web. This is one of the advantages with this pattern teaching mode is that if there's something wrong with that setup and there's something in the background or any of those, all of these things get disregarded. And likewise, if this web breaks, you will immediately see that it shows that hey, I'm supposed to see a web there.

There's nothing there. And it shows the width computed as zero. And then when the width comes back, you can see that value there. And then likewise, if you move the web, it will keep track of it.

As long as the width goes uh or the position goes way off, then the the width goes to zero, it says that, hey, I'm supposed to see a web in that location, but the web has moved. This just means that the blade has moved, and then it will lose that pattern. Again, for the web 4, it does the same thing, but web 3, web 2, and web 1, they're all in the right location. So, as soon as this comes back within a certain tolerance, then it picks that up.

And likewise, it picked it up within that certain tolerance of the initial position. So, the pattern teaching mode allows you to have a much more robust measurement in there. So like I mentioned there are other videos that talks about some of the functionalities with regard to setting the upper limit, lower limit, nominal width and how to teach each individual webs. So one of the other things with this app is that now you can take all of these widths and plot them and save them.

You can do that by going into this width data page and right now it is showing all the widths. We have five web widths and all of those widths are shown in a real-time plot and you can see that right there. And then there's also a table that's showing that actual value of all of these and you can see that in the bottom table. A general use case would be that you can enter a job number.

Let's say I want to say shop order number 43768. Whatever you want to do, you can enter that there. And then you can also set the the time scale. So 30 seconds or 1 minute or whatever you want to do for that.

And you can selectively enable or disable a width. You can say I just want to see one web width. Okay, that one width five. And then you can enable that width one, width two, three, four, and five.

You can see all of those widths there. And then you can download the data. What it will do is download the data to a folder that we had set up initially. So that's what it's downloading it to.

When you download the data, it's going to give you a lot of different information. We're downloading the width data and the name we gave the top mandrel goes into the file name. The IP address of the device is also in the file name and then the job number also comes up there. If we open that let me show you this data that got opened.

You can see that it's got the device name which is top mandle, IP address, the job or the sales order number is there and then each of the widths that we have is there. So width one, width 2, width three and width six and and all of those widths that we recorded five widths that we have got a time stamp. I think it's about four times a second it records the data and you can open this up in any CSV application Excel or something like that. Like I mentioned we can selectively save the widths.

So you can say that hey I just want to see the width to width three and when you do that you will get the same thing. Now we have the new data. And if I open the new data, it's just showing you width 2, width three, and width four. Those are the width that we selected.

It only selectively downloads that data. It's all timestamped. For certain customers, they actually want to label the widths. So especially in lithium ion battery application it could be that you want to say this is a trim one width and then trim two coding width and then you can say tab one width coding two width and then you can save the labels.

Now all of these are as per what you had labeled and when you download the data it will have those labels in there. Just a userfriendly way for you to label these instead of having some abstract width 1, width 2 and width three all of those kind of things. And then there's also an option for you to automatically download the data. I can set this up to download the data every minute.

Once that time hits a minute, you would have a new set of data downloaded automatically so that nobody has to manually go in and download this data. You can go make other changes and do other things while waiting to get that data. It'll automatically hit that limit. I will put this to the side and you should be able to see that as we get a new time stamp.

You can also go through this and change the time scale. You can see four different time scales 1 5 and 30. And likewise there's also a lot of different time interval options that we have. So you have 1 15 and all those kind of things.

Okay. So we did get another data come in here. So that came in a minute later. So it starts at 57 4957 and then you have the data after that minute comes in.

The first time when we download this it is going to download a lot more data than that. From then on the second time onwards it's going to download exactly 1 minute of data. The first time it's going to show you all the data that picked up until then. It started at 3:49 57.

At the 1 minute instant it downloaded all the data. Now we got a new data at 5637 and this would be exactly 1 minute. So and then 35637. From now on it'll be exactly 1 minute data.

So you can set this interval to whatever interval that you want and you'll be able to download the data. We have another option where if you don't want the plot and you want to see it as a table, you have an option to see it as a table. So you just click on this and you can change between plot and table view. And then you can also change how many rows you have in the table.

You can set more rows if you want to. The table gets updated every 1 second. If you have 30 minutes, it will have the data over that depending upon your application. If you want to disable a column, you can always press that.

It will disable the column. If you want to reenable the column, you can press that and reenable the column. Just like in the plot view, if I want to disable a row, let's say tab width, disable that, enable that. Just a simple way for a user to collect data from our system.

No programming needed. Everything is done automatically by us. So it allows you to install the system, have complete control over the system and download the data without writing a single line of code. That's essentially it with the app.

To set the download folder, you can click on that and select the download folder. Now that we have run this app one time and registered a controller, I'll show you what happens when you reopen the app. I can close this and then I'll reopen the app. When I do that, it's going to create this interface.

It says that you've already registered a controller with us before. So, it automatically picks that up. Then I can click on that and it opened the app for me. Now, if I go to the well, obviously you can go to the sensor config, but if I go to the width config, it already has my labels.

All my labels are still there. I don't have to worry about reabeling them. My job number is already there. If I need to change the job number, I can change the job number.

And the data storage interval is already there. And if I go back to opening that download folder, let me bring that up. While we closed and open the app and all those things, it's still continuing to collect the data. So 35837, it did another data download and then I think we're right at the 1 minute mark.

Once we hit this 1 minute mark, we should see another data download. So essentially, we have a way to keep track of the state. There we go. There was another one that downloaded at 4 minutes.

So we have an ability to keep track of the state. Now if you have another controller, the other controller will have its own state. So you can label all of those things. bottom mandrel and you can say things like what is the trim four, trim five, coding four, coding five, whatever that you want to set and we'll be able to keep track of that.

So essentially we are making it really simple for our users to be able to interact with our system and do that from any computer. In fact, any computer, you can open this app and run it and be able to connect to the device within your network. So, that's a quick overview about the width measurement application with our app. Please subscribe to our channel and make sure to enable notification.

We look forward to working with you. If you have any questions, feel free to reach out to us. [Music]

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# Advanced Sensor Capabilities for Converting Industry

URL: https://r2r.tech/videos/advanced-sensor-capabilities-converting-industry.md

Roll-2-Roll Technologies has released a new feature for it's web position sensors. This feature benefits all converting operations. The advanced contrasting capabilities can detect the smallest changes in colors and markings. Stay tuned for more information about our advanced contrast sensor capabilities for converting operations.

## Transcript

hi this is pivotal Velasco of roll-to-roll technologies today we're going to talk a little bit about our contrast sensing technology in how it works with our web guides you should typically some of our customers come to us a very very special situation they might say for example oh I want to guide this material but they really don't know how how to how can we get something that has gradients that you know that has no line in it well we have found a method of doing that we can guide based on it labels on the edges of labels we can guide based on features or contrast between colors and we'll talk a little bit about that we can even guide on labels that have irregular features as long as we can find something that we can guide through so today we're going to talk a little bit about what each one of these features how to go through our menu of applications for contrast sensing in web guiding applications so when you go to the screen you will see that there's a tool icon right there let's press on that tool icon that tool icon was tickets to another screen where you can see that we're on the sense sensing mode right let's hit the tool icon on top again and then we get the different this is the the screen where you will get all the different options for doing the contrast sensing in this case when it's red it means that it's already set on a specific application so now what we're gonna do is let's see all the different applications you can do by hitting on that icon there it will turn green and it'll show all the different applications now right now it's showing what we consider to be the most robust application that is it's actually seeing the border of both borders of a specific contrast in this case it can be a single color but it's actually working on two principles one it's the color and the second is the width that of that line or that color so as long as it sees that it will continue to guide or follow that based on that that is the most robust application we have for contrast sensing however the next most robust applications are actually the two on the end in this case when we hit it there it just means that it's going to look in a contrast on on a color that it's represented right now but this orange bar but it's looking and where that contrast begins from this side right and on the other side does the opposite right so in a second we'll see all these applications in working right and the least robust but it's still very useful is this one where it actually looks at to contrast and and then it looks at where those two countries are actually occurred okay so once we select that we can actually go with these two icons on top we can actually select which one of those in a specific contrast setting we can which one we will select and we'll show that in a little while when we do our applications so if I want to just set I just hit this icon again and now it's on the on this application which is looking at the other line that is caused by two different contrasts in there right and then I just hit back on the home button and takes me back to the original screen so I'm not going to show you different applications with some materials that I have here so for example we can have an application where we have labels printed on a material but you can see the labels only have this permanent edge and on this side it has an irregular feature so one application that we can do is we can actually tell the the system to look for this edge right here now this is one of the most interesting features of our sensors even though these are different colors and ingredients we can still guide on this line right here and even though there's a break in between there's a special condition in our in our in our system where what it will do is if it's in a guiding mode as soon as it sees this this break it will actually lock the position of the web guide at that and then once it sees it the the contrast again then it will go back to guiding mode so of course if this is moving really fast it actually you can't really see when the web guide stops when the locks in place because it just keeps on okay that's one application another application we'll talk about it's this one see in this case we have something similar but but we can actually we have several options to guide from we can actually guide with this in the middle and we can use the most robust application which is actually saying this is a bar right down the middle even though you see that there's a gradient there because of a way our sensors and controls are made that technology that we have it actually looks at this as if this was a line of a constant width so we'll see that application there and of course when we're talking about the lines just the least robust but it has a very good application in the case like this where you have orange and black so we might want to guide on this transition between orange and black okay and we will look at that in a second as we do each one of these applications so let's work with this application in particular so in this case we have an irregular feature on one side but we do have a feature that is constant it's just that there's there's a constant line that we can we can call it a line and the width between here is also constant but we can guide on this feature right here right now which is the edge of all these labels right remember what I mentioned before if there's a break the web guide would lock in position until it sees that material gate and it doesn't care really if the cont if the color changes all it's looking for is this edge right here so if I position the material right here on our on our sensor one thing that we'll do is first let's go back in the in the in the system and let's go into the tool mode and go all the way back I have already pre-selected but let's say that we were here we can actually do and select this one right here which is the one that we like it's looking from this side to this to the edge right and then I can tell it here by moving right now it's actually looking at the black surface up to the edge where it starts with white but I don't want a guy there I want a guide on the white on this edge right here so I can move it the position right there and I can tell it lock it there and now it is locked and then I go back in my home program and as you can see you see this is the black material on the back this is the black material on the back this one here is this white up to the edge of the label and this is the label but as I move it let's put it right here and say it's in the center and as I move it you'll see that once it loses the contrast it will lock in position you see it keeps it all the way through I mean and that's what I'm looking for and you'll see a green line which actually tells you in this case it's actually looking at the place where this white between the labels and it has locked in position there so no matter what I do as long as I keep it there you see that the green the green line stays but as soon as I move it it picks it back up again now let's look at this application in this case we see that the best way of guiding with this material would be looking at what is constant the only constant we have here that we're sure of is that the width between this this a feature here or this label and in the other label so it creates kind of like we're gonna call it like a white line even though it's has gradients right however the width is constant throughout so we're gonna work on that one place the material right here and then we're gonna go into our menu and then we're gonna select the appropriate feature that we want so we're gonna do the one in the middle remember I told you one before that it is the most robust feature there is however I do have to pick which one I'm looking at I know it's this one and right in the middle which is the white space between the two labels so I can select it right there and then I say let's pick that and it is set when I go back to my main menu as you can see the green says that is right in the middle and as I move it around you see how it follows the material based on that but notice that when it loses it it locks in position until it finds it again that is one of the main features of our system now in this case we want to do something very interesting we might have a feature which is kind of hard to detect in this case we have orange and black we want a guy by the line that is created between that transition from orange and black so what we do is we go back in our menu right and then we pick which one we want and we're going to pick this one right here now here's something very interesting once we I have picked it I can also say I can have to I have to select it right through here so what I know is right now the transition this bar right here is the orange this is the black this is the white and I can move it around I can say pick on this one or pick on that one ring but I want to do this one which is a transition as you'll see you'll see a green light or a green line that goes around the two features right and it's going to be right in the middle there where the transition occurs because I picked that one which is right in the middle here I can go back in my menu and you can see right there where the Green Line is right where the black and orange meet right now what is a special that this feature is that it will only look at where orange and black comes in that arrangement Orange on this side black on that side you know we'll just follow that feature through me and if it loses it like before it just locks in the last position but then when it's picked it back up he keeps alone now I have another orange in black but if I put that one there see it's not gonna pick it up it's not on the right orientation right so that is one of the features another feature that we have with this so we hope that this information is of value to you we know it should be we're really interested in knowing any other applications you might think of however think of this we have a web guiding technology that uses contrast sensing that can handle very difficult applications where where the contrast has really has some some very specific features such as gradients maybe irregular features as long as we can find something where we can guy from we can provide you a good guiding system based on contrast you can see more of this in other features that we have in our in our products by visiting our website which is WWF tag team thank you you

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# Advanced Sensor Capabilities: Edge, center, width, contrast and mark sensing

URL: https://r2r.tech/videos/advanced-sensor-capabilities-edge-center-width-contrast-and-mark-sensing.md

Check out the many capabilities our sensors have in edge, center, width, contrast and mark sensing. Our sensors require no calibration. These advanced sensor capabilities are shown here in this video.

## Transcript

This Pedro Velasco with Roll-2-Roll Technologies And we want to show you a little bit more about our sensor technology and its different applications. So here we have a demo set up to show some of the features that are sensors have. Right now we're showcasing the 221 infrared sensor and on the left side you'll see the forty eight millimeter white light sensor which we used mostly for contrast sensing so we have already set up the Infrared sensor and we're going to do first let me show you the in the edge mode all the capabilities that it can do. So they can do so right now number one.

It can actually tell you exactly where the sensor is mounted and Which side is that it's that said its absolute sensing so as you can see it automatically detects a sensor And then it's affecting the edge on this side, right? but I Want [to] change it. Just press here if I come from this side? See it automatically detects no calibration needed for this operation.

Additionally we have other characteristics that we can do with this we can do something with this same sensor. We can measure width. We set it up to monitor in this case. It can be a pass or fail condition so now there's no material, so I'm gonna put a material here, and then I'm going to set a Condition and I'm going to set it up.

Let's say I want to accept two millimeters off That's accept so now it has recorded the distance that just width that I want right? but put another material, that's a different width It will leave me a fail condition because it's beyond the limits that I've all already set up over here So that's another characteristics of our sensors. We can also show you another which is the string mode right here for the 221 sensor if I present one string? will actually see one string.

But that is the same time you can also see two strings and you can see even Three and many more right, but the best thing that we can do is we can actually also give you the distance between the strings between the edge of the strings, so in this case is telling us between the third and First string there's Thirty six millimeters right however we can adjust this, prepare you with our system so that they can actually tell you the difference between individual strings Now let me hook up now our White light sensor so as you can see I'm just going to unhook our 221 sensor infarred sensor And then I'm going to just hook up The light light sensor as you can see it turns on immediately It detects it and of course a white light sensor can do edge guiding. All right Just this the other sensors You can do it from either side, it auto detects. But I can also select the mode So right now. It's going to do contrast sensing So it will tell me The position this contrast as you can see by that?

Green and Red bar right, but I can also tell you Not only that I can tell you the width of that So it gives us a 9-millimeter width, if I change it and see, it changes. of course, if I Had a steady hand this little better, [okay]? [okay], so that's one of us the many features that we have and that's with the white light sensor the contrast capabilities also, we [can] also give you a Mark so let's say for example. You have something like [this] We wanted to detect the mark, so as soon as the sensor sees it It will tell me that the mark is detective.

Mark detected. This comes across, so this has multiple applications if you had For example. We can actually give you the distance between marks through a one of our algorithms But the best thing we can do is, we can also do this with ultraviolet light and then you can have a mark with UV ink which can also be detected. So these are some of our capabilities that are sensors can do.

Of course now we're looking for other applications As we do our research in our developing products by right now these are available to you. Just give us a call or visit our website, and you can actually see your products there. Thank you very much

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# Advantages of the ODC Sensors and SCU6x Controllers for Multiple Web Width Measurement

URL: https://r2r.tech/videos/advantages-odc-sensors-and-scu6x-controllers-multiple-web-width-measurement.md

Unveiling the Advantages of the SCU6x Controller & ODC Sensors

In this episode of the Multiple Web Width Measurement Application Series, we explore the SCU6x Controller and ODC Sensors. These advanced technologies not only guide but also measure the width of single or multiple webs with precision. The ODC sensor stands out with its one-sided sensor technology, simplifying installations in tight spaces and offering a one-to-one magnification, ensuring high resolution even for wider measurements. Ideal for various applications, especially in existing slate rewinds, this comprehensive guide highlights the unique benefits of incorporating ODC sensors into your setup.

00:00 Introduction to SCU Six X Controller and ODC Sensors
00:25 Advantages of ODC Sensor Technology
01:31 Technical Specifications and Performance
01:55 Applications of ODC Sensors

## Transcript

One of the key things with our SC6X controller and the ODC sensors is that [music] they not only are used for guiding purposes, they're also used for any type of cross machine direction width measurement applications. It could be measuring the width of a single web or multiple webs. Here again to reiterate on some of the advantages of the ODC sensor is that it's a one-sided sensor technology. So it allows us to install the sensor in tight installation spaces whereas a camerabased traditional machine v machine system might need a long longer field of view and working distance which creates issues if you want to add an width measurement system to an existing machine.

The other advantage is that the light source, the optics and the camera, everything is built into a single interface like what we have here. We don't have to have a separate light source or gantry [music] to have the camera and the light source built in. The third advantage is that the sensor provides a one one magnification. If the object is 100 mm wide, we're using a sensor that is at least 100 mm wide.

So, we get a one one magnification. The advantage is that when you go to a wider width, you don't lose any resolution. So for example, this ODC 960 which is a measuring range of 960 mm can provide the resolution of 127 micron on the camera level and then sub pixel with that you could get up to about 33 micron resolution. your resolution is not affected by the field of view that you are requiring.

Because of these advantages, the ODC sensor is used for a lot of different applications, especially in existing slitter rewinders where you want to measure the width of the material.

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# AIMCAL R2R 2020 Conference Exhibit

URL: https://r2r.tech/videos/aimcal-r2r-2020-conference-exhibit.md

Roll-2-Roll Technologies will be present at AIMCAL R2R Conference with a virtual exhibit and a presentation on Advanced Web Guiding Concepts and Applications

## Transcript

welcome to roll to roll technology's virtual exhibit at aincal r2r 2020 conference my name is pedro velasco and i am one of the executives and co-founders of roll-to-roll technologies this year we are participating in the r2r conference with a virtual exhibit and a presentation by my colleague dr otto vince chadri his presentation is on advanced web guiding applications and concepts within the web handling track the presentation is on wednesday october 21st at 11 45 am central time after the presentation there will be a live q and a with the expert panel in the web handling track which will include dr sachadry our company has been in the industry for a little over six years we're a spin-off of oklahoma state university home of the web handling research center our entry into the converting market was spearheaded by our advanced technological developments in sensors and controls for web edge and contrast detection with this we have been able to offer the converting industry a technology that allows for handling of any type of material without the need for calibration increased sensing ranges without loss of resolution through the sensing range inability to tackle challenging applications that are not possible with a traditional sensor and control technology that was available until we came along our product lines are grouped in three categories web guides sensors and controllers in web guides we offer intermediate guides such as displacement guides or offset pivot guides and steering guides terminal guides for unwinds and rewinds and upgrade kits to replace control sensors and actuators on old web guides or new hydraulic web guide systems for our sensor line we have sensors from 48 millimeters to 900 millimeters in sensing range with different light sources to accommodate for a wide variety of applications in web guiding and monitoring our controllers have a variety of options that allow for our customers to adapt to their applications however our strength is in our practical technological knowledge and web handling and our complete focus on solving our customer problems we have solved issues such as measuring the width of a web within a web by using our contrast sensing application guiding different fabric materials without having to stop to calibrate sensors monitoring webs in locations within a converting line that are not accessible to fork style sensors or monitoring multiple threads in a process and so on our technology can be used to detect flags placed for marking defects to detect splices and other defects on the surface of the web we thank you for visiting our virtual exhibit and we hope you have a valuable experience at the conference don't forget to attend the presentation on advanced web guiding applications and concepts and we invite you to schedule a live online demo with us during the show

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# AIMCAL R2R 2020 Conference: Advanced Web Guiding Applications and Concepts

URL: https://r2r.tech/videos/aimcal-r2r-2020-conference-advanced-web-guiding-applications-and-concepts.md

AIMCAL R2R 2020 Conference: Advanced Web Guiding Applications and Concepts

## Transcript

good morning everyone this is aravind se chadri from roll to roll technologies i'm here today to talk about advanced web guiding applications and concepts before we begin let's look at some of the basic concepts regarding edge guiding center guiding sensor positioners moving sensor center guide what do we mean by guide point what do we mean by remote guide point uh what is a dead band and what is edge filtering we will use these concepts to build on so that we can look at how some of the challenging guiding applications can be solved uh by uh some of these things that we initially cover so uh everybody is familiar with edge guiding if not edge guiding or guiding basically is to align the cross machine direction position of the web within a roll roll-to-roll machine so you're laterally positioning the web at a certain location in the cross-machine direction of the web this is typically done with a single sensor and the sensor measures the position of the web and sends that information to a control system and uh based on the measurement and the reference there's an error that is computed and then the control system sends the command to the actuator and then the mechanism uh the web guide mechanism moves the web and then this is a closed loop control system that keeps going on typically one sensor or two sensors are used and in a single edge guiding application the sensor may be installed on the drive side or on the operator side depending upon what is required and then the sensor is typically positioned at a constant or a predefined uh reference within the machine so that the web can be guided uh to a certain position within the machine now the main issue with a single sensor web guiding application is that um whenever the web width changes then somebody has to go move the sensor and uh depending upon your process uh if the process is aligned to the center of the machine or if it's justified to one side of the machine the sensor might have to be moved at different locations and any time when you have to move a sensor that causes downtime and it also introduces an opportunity for error and operator error so that's the main issue with edge guiding with a single sensor and and apart from edge guiding there are some situations in which center guiding is used where you have two sensors each of them looking at one edge of the web and then they send the signal to the controller and the controller averages those two measurements and then based on that average measurements it computes the error and then it moves the actuator based on the error the main reason why the center guiding is used is in applications where there is an inherent possibility of a slight variation in the web width let's say you have an extrusion process you're extruding the web but it's not a a straight edge it might have some amount of variation there to reduce the effect of either justifying to one side where you you might have a perfectly round roll on one side and then a really jagged uh raw uh edge on the other side it's common for um manufacturers to use two sensors to center guide the web now even with the center guiding application when the web weight changes uh somebody has to move the sensors and again like um a single sensor you need to move it at the right location and now you have two sensors that needs to be moved and then these two sensors have to be positioned exactly equidistant from the center line uh all of these causes time and if there is an error then it causes downtime as well so in order to avoid this some manufacturers have what is called as automated sensor positioners instead of manually moving the sensor you can automate that by connecting an actuator to the sensor and you can move one or two sensors based on what product you are running and you can automate it by setting all of those into the plc so that based on the product code the sensor is moved automatically this does reduce the downtime and then it also helps reduce the operator error but this system is a little bit complicated um because you have a system lan an actuator it needs another control loop to move the sensors and if those sensors have to move automatically without an operator kind of pressing a button to get it to the different location then you have an additional control loop in there and that increases the complexity of the system and then when you have an additional control loop you also need to tune the control loop so if the web width kind of varies like like this and if the sensor is automatically moving it's oscillating back and forth then the gains of those system has to be uh adjusted just right so that it doesn't never miss the web and then it's not too aggressive that it can run into the web and damage the web so this increases complexity additional actuators additional drives that are involved and overall it adds more mechanical wear and tear to the system um a better way of doing this is to just have a white sensor uh if your sensor is wide enough to accommodate any web weight variation then there's never ever a need to move the sensors and you can put one sensor on each edge so you have a center guiding sensor center guiding application with two sensors and with the web width varies and if the sensor is wide enough to see all of the variation then you would never have to move the sensor and you can still do that one of the key things in accomplishing accomplishing this is uh basically what we call as a guide point so when you have a single sensor and you're guiding the web uh based on the measurement from the sensor the control system is going to use a reference signal and that reference is usually the middle of the sensor's position measurement so if the sensor has an output of 0 to 10 millimeters and 5 millimeter for example would be the reference and if the web goes at four millimeters or if the web is at six millimeters then there is an error that is being created based on the magnitude and the direction of the error the uh control system sends the command to the actuator to move the web guide and most most often the guide point or the reference is in the middle in this case it's 5 like what i mentioned now instead of moving the sensors manually what can be done is actually move the reference within the sensor so instead of guiding to five millimeter when the web weight changes you can guide to two millimeter as the reference so if the web is at one millimeter it creates a negative error and then when the web is at three millimeters it creates a positive error and now your guide point is moved to two millimeters and this is what is called as an electronic guide point change the main advantage with the electronic guide point change is that if you have a sensor that is pretty wide and let's say you have a sensor that is 17 inches wide then any web width variation you don't have to move the sensor so that the web can be guided to the middle of the sensor you can just electronically move the guide point to a location so that the web can be guide at that location and this is a simple uh thing that can be done it's easily it can be automated easily and then you don't have any mechanical wear and tear because everything is fixed and you never have to move the sensor and this is what is illustrated in this uh animation here where if the guide point is to the left or to the right then the the reference for that control system uh is going to be at that location and then the actuator is going to change direction at that arbitrary location so you can technically have the guide point anywhere within the sensing window uh but it is very common to limit the extremes um so that you don't put your guide point all the way to one edge or all the way to the other edge the main reason is that once the web moves past that edge irrespective of where it is it's hard for you to know what's happening there so you you want a little leeway so that you don't go all the way to the extreme on either direction so uh it could be like you can go up to 90 of the sensor range that's where the guide point can be changed uh but within that remaining five percent on either side you cannot change the gate point uh so this this is what is called as an electronic guide point change and it's very common especially with a wider sensor and this enables operators to not to move the sensor and have a quick product changeover and then when we do center guiding the guide point change actually doesn't you don't need to do a guide point change when you do center guiding especially with two sensors and that's what this map is showing is that even if you move the sensors uh on either direction the guide point doesn't change so this is making it a lot more simpler so center guiding with two sensors is a lot more simpler than uh edge guiding and then even when the webwork changes you never have to change the uh guide point so these are the advantages like i mentioned center guiding with the white sensor is a lot more simpler reduces uh the mechanical wear and tear inherently it averages so that's like a filtering and then it's a simple to install operate and then helps you with the quick product changeover and then you can use this sensor to as a web detect sensor and as well as to monitor the width of the web because you can see both edges of the web another concept that is commonly used is what is called as a dead band a guide point is the reference from which the the the uh error sign changes now dead band is a region around the grade point where we can still say the error is zero and then uh beyond the deadpan is when the error becomes paused toward negative and uh this is done mainly to avoid any issues with uh artificial uh edge position variations that are created by edges that are kind of fuzzy or rough where the web is actually not moving just that the edge is kind of jagged in order to avoid the web guide from moving back and forth we can use a dead band onto it and finally a concept called edge filtering it's basically uh instead of taking the measurement instantaneous measurement you can filter the data uh in time and a typical filter that is commonly used is an exponential moving average filter and this helps in significantly reducing the variation of the edge position especially when you have some kind of an edge that is jagged and it's not really representative of the actual web position but just that the edge is kind of jagged like that this plot is just showing how if you have a standard deviation of 7 and then if you do a filtering for example you can reduce that variation by 50 and then if you do an averaging with that you can reduce that even further so the top plot is showing the measurement from one sensor the bottom plot is from another sensor and then the middle plot is the average of those two sensors that would be the center line center guiding kind of thing uh so some looking at some examples um let's say you have an edge like this um the web is pretty uh jagged and this is from an extrusion process now you don't want to take the instantaneous measurement and guide the web because the web guide is going to be oscillating back and forth it's going to be crazy what better way to do this is to use two sensors so you get an inherent averaging of those two edges and then add a dead band basically if you have an idea of the profile of this edge that is varying based on that you can create a deadband value and then filter the edge position so that the the steady state or the gross position of the web would be at a fixed location then even when the edge measurement is not that great you can still have the web guide to not oscillate um instead of there are situations where you deliberately have an edge with a certain profile like what is shown here and it's got a sawtooth kind of profile the main problem with this is that none of the conventional techniques would work because that when this web goes underneath the sensor and you're looking at that edge position depending upon the speed depending upon the sensor measurement frequency and depending upon the duty cycle of the sawtooth wave when you do any kind of an averaging you're going to shift the guide point you're going to have that average move whenever any of those conditions change for example let's say you're running a thousand feet per minute and you do all of these things and then now you go to uh 2000 feet per minute that's going to cause a shift even if you do any kind of an averaging so temporal averaging or time based averaging is not a solution for that but a spatial averaging or spatial filtering is a solution in this case you would align the sensor vertically along the machine direction and then have some kind of a like a bang bang control to be able to guide the web this is a technique that we use to guide some of these webs like this another common problem that we would see is uh wrinkles uh basically what uh wrinkle is that whenever there's this trough and the valley that is created on the web it's going to suck the edges in and out in and out in and out based on how the wrinkles are flowing and this is going to cause an edge position variation which is not representative of the web position the edge may go in and out but the web may be still in the grass position so this affects a lot of systems and the best way to tackle this is to do center guiding and based if you have any information about the wrinkles you can have that use that in your infinite impulse response exponentially moving average filter to reduce that effect and then also use a deadbend so depending upon how much the width variation is you can put that into your system so let's say the wrinkle is causing the width to change by a millimeter then you can have half a millimeter of deadband on either side and that would make sure that the wrinkle is not causing the web to oscillate but in reality these are all kind of like a fixes and these are not real solutions for the wrinkle problem and in this case you have to go and fix the underlying wrinkle problem but to avoid the web guiding from oscillating these are some things that we could do and finally uh there are situations where especially in diaper manufacturing or non-moments where you're running a porous web and then the sensor that you're using to run the porous web is affected by the porosity of the web and what it essentially would do is depending upon the density of the web underneath at that instant when the sensor is making the measurement that's going to change your output of the sensor so the output of the sensor may be varying based on the density of the web at the instant that you are measuring this will cause an artificial variation in the edge position which is unwanted and the best way to avoid this is to use a sensor that is more accurate that is not affected by porosity variations and density variations and if you cannot do that then the the other best way to do it would be to do some dead band and filtering and depending upon how much accuracy you can achieve so whenever you add a dead band and filter you are reducing by adding deadband you are reducing the accuracy that you can get and then by adding filtering you are reducing the dynamic response or how fast your uh system can correct that error you are reducing those so it's a trade-off based on uh what is uh what is the ultimate objective and this is just an illustration kind of showing like when you have an artificial edge position variation and then when you do a center guiding you can see that the middle plot is the set the top plot is one sensor the bottom block has another sensor and then when you do a center guiding where you take the average of those two just by doing that you you're reducing the variation and then if you add a exponential moving average filter to it you're reducing it further and then if you add a deadband to it then you are reducing that even further so this is shown in this table here and you can see we start off with about one millimeter of standard deviation and then by just by filtering we got about 40 improvement and then if you do filtering exponential moving average and dead band you get about 70 percent reduction in the variations and again these variations are artificial so um the dead band and the exponential moving average uh the filter time constants have to be designed based on that information that hey how much is the variation and things like that all of these can be avoided if you use a sensor that is not affected by any of those uh finally the the uh whenever we are looking at uh guiding a web there may be situations where you might want to guide multiple webs um and this is true in lamination or coding or extrusion lamination any of those scenarios in those cases you can typically guide two layers of the web independent of each other and then guide it to the same machine reference then you can achieve a proper lamination at this point but the main problem with that is when the web weight changes or if there's uh any centerline guiding uh kind of application then you need a little bit more uh coordination between these two systems these two layers the web one of the things that has been done mechanically is to chase the web and in that case you have a web master web that is there and then there's a sensor that is installed to chase the web it means that if the web moves uh one inch on one side the sensor would actually follow and chase the web so there's a control system that is kind of chasing the web and that particular sensor is connected to the other sensor on the other layer and this basically means like okay if the web moves on the bottom one inch i'm going to move my sensor one inch on the top and this is done automatically so there is a control loop that is uh moving the sensor positioner mechanically obviously you can see that it's a complex system there's too many mechanical parts and then depending upon how far these are then the mechanical coupling is going to be an issue and then if you want to do center guiding with this kind of system then it just the complexity goes pretty high pretty quick a better way to do it would be to use the guide point or the electronic guide point adjustment so you do have a sensor in the bottom the master sensor that is going to look at the position of the master web and then it's going to provide a guide point adjustment to the sensor on the top uh so that whenever the master web moves the top guide point of the top web sensor also moves and that makes sure that these two webs are coordinated if you have multiple webs uh multiple layers then we do the same thing as what we did in the in the in in the previous example the only other thing is that there are two now two different web guide uh sensors uh whose position needs to be varied so this is accomplished by slaving one of those so this is a slave actuator um and this is the uh the master actuator that is connected to this chasing sensor that is looking at the master web um this you would see uh commonly in metal industries uh in lamination processes uh again it's pretty complicated uh especially mechanically and then the synchronization it's a common problem synchronization meaning that one actuator has to be exactly synchronized with the other actuator otherwise this causes uh issues with the performance and then any lag or a slow response in one is gonna provide a overall uh worse response for your system uh the better way to do it would be to use an an electronic guide point adjustment i just used one sensor that's going to monitor this master web and then change the guide point of the other slay webs or the follower webs so that you can guide the web to that location now the main considerations with coordination is that if you have this master sensor wide enough then you can have the sensor basically look at any variation of the master web and the master in the examples that we showed there the master sensor was just used for measurement but technically you can also have a web guide on it and that web guide is going to guide the web uh on the master web and then that measurement can also be used to change the guide points on the slave or the follower webs that can be done as well and usually uh this has a good result if if we can have the web path links with these different sensors and web guides from that sensor to where the lamination process is if the web path links are the same and that provides the best results especially with dynamics and things like that but if you can't then you can use some kind of a feed forward term to compensate for the additional spans that you have to work with and then you can also do a dead band or a feed forward offset in these kind of things if you have to really put the sensor farther away from where you need to guide it so that's uh a quick overview of some of the uh things about common things irrespective of what kind of a control system that you have some advanced way of guiding concepts now we'll talk about some of the common control systems that are there in web guiding systems we're just going to quickly go through some of these things most often this is not addressed quite a bit but we're going to take a quick job at it and then there are basically three main kinds and then most of the web guides that are available in the market are fixed gain control systems and they are feedback control then proactive control is a new concept which is kind of like the future of web guiding so in a fixed gain web guiding control system as the name suggests the gain is fixed and like i said a lot of people don't really know what's inside a web guiding system there are multiple loops there's a current loop there's a velocity loop there may or may not be a position loop and obviously there's the outer edge position loop uh all of these loops have gains and these gains have to be tuned and the main problem is that this web dynamics term right here and that depends upon how fast you're running what is the tension what kind of elasticity of the web that you have how is the web guide installed all of those influence that and then anytime you have a product changeover that can significantly change any of these dynamics then the controller has to be tuned otherwise it's not going to provide a good performance most often most web guides the controllers are not well tuned that's a problem now to overcome some of these there are some other techniques called as adaptive control the main idea behind that is instead of having a fixed gain control system uh you have a controller that adapts and it learns uh based on the current conditions and it can avoid any sensor gain issues like the porosity issue that we talked about before it can overcome those it cannot adapt to the mechanical dynamics like the motor response and things like that and also the mechanical advantage of the web guiding system all of those things can be adapted too and this is a little bit more advanced control system and this this is something that is also available another way of doing this is called optimal control in this case uh what it's done is uh if you know different conditions in which your web guide is going to be operated under with what all the different materials that you're going to run all the different transport conditions and all different installations if you have to then an optimal uh controller a fixed gain controller can be designed uh so that it works best under all of these different conditions and the optimal not just means in the control system but also in the transport conditions uh the installation and things like that so this is also available i don't have a reference there in the bottom but you can look at optimal web guiding on google search and you would find papers about this there and finally uh there are other control systems especially those used in rolls-roll products is what we call as a non-linear trajectory control in this case we control trajectories for position loop velocity trajectories and also have a predictive component to it and essentially it provides you with a pretty good response uh system which is well damped and in this case we could achieve up to about 135 145 millimeters per second correction which is kind of unheard of in the industry and finally this is kind of the future of web guiding and this is what we call as proactive control instead of reacting to the edge position variations uh can we be proactive about it and this is something that we do and one of the things to hear the key thing here is that we have to first construct a performance index and then see whenever the performance index changes what are the deterrents or what are the things that are affecting that performance index is there a pattern to it and from that pattern can we see what is the root cause let's say there is an uh roller or web guide that is misaligned upstream can we detect that and then can we provide that information to the operator so that they can go in and fix that problem rather than trying to react to it an offset in a upstream process will actually limit the actuator stroke on the web guide in the downstream process and this is unnecessary if you can detect it and that's the whole idea behind a proactive control it could be offset there or a sinusoidal disturbance or any of those kind of things where it could be material process or machine and a product of control system would be able to identify and provide some solutions for it so in summary um some of the advanced web guiding concepts that we saw uh that the simplest thing that anybody can do to get a good guiding performance is to do center guiding and center guiding with wide sensors would significantly simplify your operation if you need to do dead band or if you need to do edge filtering especially you have some harder materials you can do that but essentially have a sensor that is unaffected by material property variations that will help you coordination can be achieved with electronic guide point adjustment and then the future is in proactive control do not react to the problems be proactive and kind of figure out what is the underlying cause for it and how that can be fixed in your machine that's my presentation thank you for my for your time there are some additional resources here and also my contact information um and how you can reach me unfortunately i would not be available for the q a session but i've asked one of my colleagues to be there so hopefully if you have any questions you would be able to address thank you so much for your time have a great day

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# AIMCAL R2R 2020 Virtual Conference - Invitation to our Exhibit of Web Sensors and Guiding Applications

URL: https://r2r.tech/videos/aimcal-r2r-2020-virtual-conference-invitation-our-exhibit-web-sensors-and-guiding.md

Roll-2-Roll Technologies LLC is hosting a virtual exhibit at AIMCAL R2R 2020 Conference. The conference is slated from October 19th to October 23. If you are attending the virtual conference you can benefit from visiting with us to discuss web guiding and web sensing issues in your converting operation. Dr. Aravind Seshadri will give a presentation on Advanced Web Guiding Applications and Concepts on Wednesday October 21st at 11:45 am CT, and will be available for a post presentation Q&A for the Web Handling Track right after his presentation.

## Transcript

uh rolls roll technologies is going to be at the aimcal r2r 2020 virtual conference uh starting next monday and um i just wanted to uh just invite you that if you're attending the conference um pay us a visit uh on our uh on our virtual uh exhibit that we're gonna have there uh one of the things that you're gonna see there is our uh wpes 900 infrared sensor and um it's an amazing sensor i mean it has 30 over 35 inches of uh sensing range it can detect up to 200 over 250 different edges and at the same time it has a resolution of 5 000 of an inch or the entire sensing range now if you go over to our website you can see more about this but actually take an opportunity during the conference to just visit our exhibit and talk to us and then maybe schedule a demo during the that same time uh also we're going to have uh dr arvin sochadri he's going to make a presentation on web guiding on advanced concepts in web guiding which i think is going to be a very of good use to anybody who's interested in the technology behind web guiding and things that are relative to it so invite you to visit us next week we have starting monday all through friday and then on wednesday at around 11 45 uh central time that's going to be our presentation by dr alvin sasha thank you and see you there

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# An Overview of Web Width Measurement Dashboard on SCU5 Controller

URL: https://r2r.tech/videos/overview-web-width-measurement-dashboard-scu5-controller.md

This video show how to access the web width measurement dashboard on the SCU5 controller. This dashboard is enabled by a built-in web server on the SCU5 controller. And the dashboard is only available with the following industrial ethernet protocols:



- EtherNet/IP
- PROFINET
- Modbus/TCP



For more information about SCU5 controller please visit: https://r2r.tech/products/roll-2-roll-controller

## Transcript

apart from looking at the dashboard with the IP address set like this we do have another web page on some of the controllers that are specifically for width measurement applications and this dashboard is for General prototyping it's got the sensor and fault information and things like that but for customers that are looking to log data for width measurement application they can go into another dashboard and that's located in the same website address or the IP address and with the extension width.htm so it looks like a similar kind of dashboard the only difference is that this is specifically designed for width measurement application so as you can see on the top it shows you the width of the web directly in inches and if you want to look at it in millimeters you can just go in and click that it's going to give you that width in there and if you have the web moving back and forth you can still see that the width is being measured and recorded everything is similar to the previous dashboard except that it's catered more towards width application and you can also set the same thing to download the settings and save it and things like that one additional thing that we need to keep in mind when we have this dashboard is that the data is actually coming from the controller and there is a web server that is running on the controller so you can have multiple instances of the dashboard so you can actually go in and open another one and have two dashboards at the same time and whenever you are setting up to download the data again you need to keep in mind that as long as the web browser is open it's going to keep doing everything if the web browser is closed or if you refresh this page on the web browser the data is going to start over every browser tab or every browser tab is an instance and the web server is serving the content and then the JavaScript on the web server is executing it and displaying the content on the web page that's the only thing that you need to keep in mind is that if you want to log the data you need to have either a dedicated computer where you can set this up and then nobody is going to disturb it that way it keeps recording the data automatically and other than that it's a quick prototyping tool to see how our system performs and what the parameters of the system are in real time once again thank you for watching and we'll have please subscribe to our Channel and we'll have more videos that talks a little bit more detail about different things from our product

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# ARIS web position sensor technology: Accuracy, Precision and Linearity with different materials

URL: https://r2r.tech/videos/aris-web-position-sensor-technology-accuracy-precision-and-linearity-different-materials.md

ARIS Web Position Sensor can automatically detect any material without the need for calibration. This video shows the sensor capabilities, such as accuracy, precision, linearity, with four materials.

## Transcript

Our web guiding system, ARIS, features the latest in web guiding technology. It adapts to any material, requires no calibration, and is very simple to set-up. Our technology allows the sensor to be material agnostic, which means ARIS accurately detects the web edge position of any materials used without the need for manual adjustments. ARIS’ sensor technology works differently than any other currently available sensor in the market.

It uses the reflection of infrared light to take a picture of the edge of the material. This picture is then processed using digital signal processing algorithms to accurately sense the true position of the material irrespective of its physical properties. Other sensors use a blocking technique where the web is used to block light, sound or air. Since the amount of blocking depends on the material properties, the current sensor technology is less accurate with porous or transparent material.

Ultimately the web guiding performance is affected by the inaccurate sensor measurement. In this experiment, we will show you four materials, black nonwoven material, white nonwoven material, transparent film, and burlap. Our experimental setup is equipped with a high precision motor stage which moves the web material, which is 10 mm away from the sensor, back and forth. This setup is used to quantify the sensor performance.

With each material we repeat the exercise four times. The green line represents linear regression, which quantifies the precision and accuracy of the sensor. The blue represents the actual position of the web as measured by the sensor. Follow the results as the experiment progresses.

The video shows the web as it moves away from the center and the sensor’s ability to follow the position. The experiential results clearly show that the precision and accuracy of the sensor is unaffected by the material properties. Our sensor has linearity of plus or minus 1 percent without any calibration. Find out more information about ARIS and our sensors, using the link in our description below.

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# Benefits of Retrofit Kits for Web Guides

URL: https://r2r.tech/videos/benefits-retrofit-kits-web-guides.md

Learn about the many benefits a web guide retrofit kit has to offer. Whether you want to upgrade an existing machine or realize the benefit of the latest in web guiding technology on a smaller budget, retrofit kits are the answer.

## Transcript

All right, this is Pedro Velasco with Roll-2-Roll Technologies. Today, we want to talk to you about using retrofit kits in order to improve your existing web line or a production line. So one of the can one of the things that usually a any Integrator or OEM or a rebuilder of machines will face even even an end-user will face is that you have a machine, you have a web guiding system, and you need to replace it But one of the things that we found out is that you really don't need to replace the mechanical components. If you have a retrofit kit You will probably get a lot of bang for your buck instead of expending a lot of money on just a complete web guide.

Advantage of this is that number one, you don't have to buy an expensive web guide system new for your operation. Number two, is that when you buy a new web guide system sometimes because things have changed through the years then you have to do a lot of adjustments within your machine such as drilling new holes, adapting your web guide to that. Number three if you get a retrofit kit, you have the advantage of getting the best or the newest technology that there is in controls and in sensors. So what you usually get when you get a retrofit kit?

Number one, you'll probably get a sensor one or two depending on your application. You will get a control unit. You will get an actuator with a motor driver and of course all the necessary accessories in order to connect all this. So those are the things that you're looking for.

Now in an additional video will teach you or will talk to you about how to do the connection of all these items so you can apply them to your lines. So if you're an integrator, you're an OEM, you're a rebuilder, even an end-user one of the best things you can do is use a retrofit kit in order to get your operation into the best technology available instead of spending a lot of money just getting a new web guide.

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# Capabilities Low Profile Web Guide

URL: https://r2r.tech/videos/capabilities-low-profile-web-guide.md

Roll-2-Roll Technologies is bringing you the latest in web guiding technology. Our web guides are now smaller than ever. You can have the same easy to use technology in a more compact envelope. Our low profile web guides require no calibration and are plug and play systems.

## Transcript

hi this is privileged old troll technology today I want to talk to you about our newest addition in our line of work this is the local contact web guy which is good for narrow web applications with the displacement guide that you go from 10 inches up to 20 inches in budget what about drinking shoes with is the low profile of it which has is reduced to about 40 inches in height but also all the controls are picking away so we have a remote control display that you can place anywhere away from me hung from the machine our remote control has all the other the same applications as our physical web guide and including every will display into operator interfaces for now while the great feature with this is you can do any type of web guy usable we can do edge and the thinner you can also a little contrast guiding so those applications where you want to guys off the the contour of the edge of a label and you can do also wine guy by changing the sensor you can do these applications and when we do for a change for many of these applications are going to present an icon only on the operation support now another feature that we have is you can get these guides with either a new path or a or a d-pad so he can get a web path or exemptions are probably go to the bottom or vice versa these are some of the pieces that we have with our new line of web guides available in the flyer we office and we can see more of the art information on our web guides at www.artoffire.com

---

# Compact web guiding system and its features

URL: https://r2r.tech/videos/compact-web-guiding-system-and-its-features.md

Roll-2-Roll Technologies shows the latest in web guiding equipment. Watch this video for an overview of our web guiding system and sensor's capabilities. 

## Transcript

our web guidance system RS features the latest in web garden technology in adapts to any material requires no calibration and it is very simple to setup our technology allows the sensor to be material agnostic this means ours accurately detects the web edge position of any materials used without the need for manual adjustments our SS sensor technology works differently than any other currently available sensor in the market it uses the reflection of infrared light to take a picture of the edge of the material this pictures and processed using digital signal processing algorithms to accurately sense the true position of the material irrespective of its physical properties other sensors use a blocking technique where the web is used the block light sounder air since the amount of blocking depends on the material properties the current sensing technology is less accurate with porous or transparent materials ultimately the web Guardian performance is affected by the inaccurate sensor measurement in addition to sensing capabilities ours communicates intelligently with the sensor watch the screen as we show how the sensor communicates with ours a green web detected indicator will verify that the edge is detected by the sensor if the sensor is not connected properly or if the edges outside the window the indicator will not really about the icons you will see a material edge position indicator when the material is in the correct position you will see one red bar and one green bar the green bar indicates the metal portion of the sensor and ideally the web should be in the green bar region if it's incorrectly positioned you will either see no green bar or you will see red bars on both sides of the green if the sensor is not within the measurable distance then the material edge position indicator will be grave the sensor position indicator on either side of the web guide picture shows the position of the sensor with respect to the guide if the sensor indicator does not register the sensor on a correct side of the web or the green bars is white on the wrong side of the web press the find sensor to automatically register at the sensor position indicator to make it simple and foolproof the intelligence and ours can work irrespective of the sensor position as long as the web is inside the sensing window if no sensor is connected or if the sensor is faulty none of the position indicators will be lit when the sensor has plugged back in ours will automatically register the correct sensor position find out more about Aras and our sensors using the link in our description below

---

# Compact web guiding system demo with Burlap web

URL: https://r2r.tech/videos/compact-web-guiding-system-demo-burlap-web.md

The performance of the compact web guiding system with a challenging porous web, burlap web is shown in this video.

## Transcript

The video shows ARIS guiding a burlap web at different frequencies and a web speed of 4.26 meter per second. Using a two guide test machine, we will show you several speeds and several disturbance frequencies that are introduced to evaluate the performance of ARIS when it handles burlap, a non-porous material. Watch the red laser to see difference of the controller when its on vs when its off. As a porous material, burlap presents a special challenge because current sensing technology is not able to handle the gaps between the threads of the material.

The image processing in the sensing technology in ARIS allows it to detect the edges of a porous material. You can find a link for more information in our description below

---

# Compact web guiding system performance with multiple materials

URL: https://r2r.tech/videos/compact-web-guiding-system-performance-multiple-materials.md

The compact web guiding system from Roll-2-Roll Technologies is powered by the ARIS web position sensor. The revolutionary sensor technology enables the web guide to work with any material without the need for setup or calibration. 

## Transcript

RS is an intelligent guiding system that uses a revolutionary fiber optic sensing technology to accurately measure web position in this video we use a two guide test machine to show how RS handles change in materials one machine creates the disturbance while one corrects this disturbance air patented agnostic material sensor allows RS to adapt seamlessly to any material including paper transparent plastic non-woven and textile without having to manually readjust the machine watch the red laser to see the difference between the controller when it is on versus when it's off you can find a link to more information in our description below e

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# Contrast guiding capabilities of compact web guiding system

URL: https://r2r.tech/videos/contrast-guiding-capabilities-compact-web-guiding-system.md

Roll-2-Roll Technologies compact web guiding system can be used for contrast guiding with the ARIS Web Position Sensor as shown in this video. 

## Transcript

our web guiding system ARIS features the latest in web guiding technology it adapts to any material, requires no calibration and is very simple to setup. Now it features a comprehensive guiding sensor that can be used in any kind of sensing including edge, line, contrast, composite or layered web detection. In this video we use two web guides as a test machine to introduce several speeds and disturbance frequencies. One web guide creates a disturbance while the other correct this disturbance.

This test allows us to evaluate how our machine adjust to these different disturbances. This video shows contrast guiding of composite web where the web is guided based on a die cut of the label. Our web guides can work with continuous or intermittent lines or contrasted edge. Our edge sensor detects the web position of any materials used without the need for manual adjustments.

A previous version of our sensor used a reflection of infrared light to take a picture of the edge of the material. These pictures and processed using digital signal processing algorithms to accurately sense the true position of the material irrespective of its physical properties. The updated version is more comprehensive and uses white light to take a picture of the web materials and in the line detection mode, the sensor can handle a solid or intermittent line or even in contrast between two materials. As you can see this video, the web guide is unaffected by missing labels.

Our tests have shown our sensor technology works automatically with materials of varying contrast. The use of fiber-optic technology eliminates a need for focusing and eliminates need for calibration and set-up. There are details on these experiments available in our white papers. You can find a link in our description below.

---

# Contrast Sensing and Options for Line Guiding Applications

URL: https://r2r.tech/videos/contrast-sensing-and-options-line-guiding-applications.md

Line guiding can be achieved even though there is not a specific line to guide from. The Roll-2-Roll Contrast Sensing Application allows the use of negative space between labels as an intermittent line. The technology behind this application allows to track such an intermittent line without the need for web speed input from the converting line. Therefore, there are no restrictions in guiding during slow down or speed up of the converting line. Furthermore, the system can track the threshold between two contrasts using the threshold as a line. 



In case the line is lost, the controller stops the web guide at it's last position. Once the line is found again the controller activates the web guide mechanism to continue guiding.



In this video we look at unconventional ways of using the line guiding application with the Roll-2-Roll® SCU5 Controller by detecting and monitoring features printed on the web.

## Transcript

Hi, I'm Pedro Velasco with Rollto-roll Technologies. In a previous video, we showed you how to teach the SU5 controller for contrast sensing applications. Um, well, today we want to talk about a little bit about one of those applications, which is line guiding. Now, converters in specifically uh slitter uh slitters uh will actually find this information very useful.

Uh we have a different way of looking at line guiding. uh mostly because we realize that there are possible savings to this and there are special situations where uh converters might find it difficult to guide a material on certain contrasting features. So uh let me go ahead and switch over so that we can see both the screen of the SU5 and our WPS uh 48 sensor white light sensor that we use for uh uh contrast guiding. So in this case we have a uh the SU5 screen on the main screen and then we have on the right upper side the uh WPS48 white light sensor.

Now, when we're looking at typical line guiding applications, we'll see something similar to this where you're just looking at continuous line uh on a printed on a web. Well, we can actually eliminate the need to print that line and uh help you in saving money from having to print additional features on your web or even by reducing the width of the web. So, one of the things that we do is first we have to go through a teaching mode where I can show you what are the different uh ways of line guiding that we have. Our most typical way is just consider something as a line.

In this case, I have set up on our sensor a black line that is shown right here with red and white on the side. If I teach it to follow that, let me go back. Forget if I teach it to follow that. And then that green line right there tells you the feature that it is following.

So, as I move this around, you can see how the sensor is capturing where that line is at. Okay. However, what if we have a special feature such as this? We don't have a printed line, but we do have something interesting.

Our technology allows us to use the white space in between the labels here so that we can consider that as a line as it goes through. If we go into our teaching mode, we just maintain that same line, but then we say it tell it to move to that space that we wanted to follow. And every time it sees that space, it will capture. Now, right now, because I'm moving this by hand, let me find a better ride there.

It will capture again every times it sees it. Right. Of course, the the uh the web has to be very stable when it does this application or any application of line guiding or contrast sensing. One of the beauties of this is that we don't rely on the information from the operation such as uh web speed.

The controller and the sensor do all that for us or do that all for you. And in this case, every time it sees this, it sees the contrast that it's following, it will guide the material to that pos or it will guide the material to adjust for that position. And when it it loses it, it stops the web guide at its last position. And then every time it catches back on, it moves the web guide or allows it to move.

So that is one uh interesting feature. However, what about if you have a feature such as this one right here where you have labels that are irregular on one side, but they're a straight line on the other side. Well, we can use the same concept of guiding on that negative space by using this right here as the edge of a line right there. Right?

We do have that application here when we look at it. and we say let's look at that web and let's look at that feature right there but coming from this side. So as you can see this is the black space of the board right here. This is the white of the web right here and this is where the label starts to be.

So these are different features inside the label but we wanted to follow this particular line right there. So we teach it to go follow that. We in uh identify it right here with a with by moving with the arrows to the feature that we want. Then we accept that.

And as you can see there's a green light the green line that tells you that is the feature that it is following. And as it goes from label to label it just keeps on falling. Same condition as the other application. Whenever it loses it, it stops the web guide and when it catches back again, it activates the web guide again.

Now, another one that we have is where we look at two contrasting features which can be shown by this right here. So, let's say I am interested in following wherever there's the red and the black. So I can actually teach that position and I do it by selecting this mode right here. And then I go and look for that condition right there.

Accept it. And then you see the green light right there. The green line where it meets the red meets the black. And wherever it sees that it will follow it.

Now if it goes to something that is different than that it will lose track of it. But once it sees it again it will again continue to monitor that position right there. Right. So those are the features that we have for contrast sensing for specifically the line guiding application.

Now, we have other ways of dealing with contrast sensing and line guiding. If you find this information useful and would like to know more, just contact us at r2r.te. Now remember, we have applications that allow you to follow a uh a line that is not continuous and doesn't require to do any specific setups on your line to feed information to our controller. Our controller works on its own.

If you like this video, just give us a like on YouTube and uh we hope to that this has been very informative for you. Keep a lookout for other videos that we will presenting in the near future.

---

# Demonstration of a Simple Narrow Steering Web Guide

URL: https://r2r.tech/videos/demonstration-simple-narrow-steering-web-guide.md

See a new steering guide system for the roll to roll converting industry. This new steering guide is easy to install and simple to use. It's a plug and play system perfect for long entry spans processes like ovens. 

## Transcript

Hi this is Pedro Velasco with Roll-2-Roll Technologies . Today we're going to talk to you about one of our line of web guides within the narrow web applications, specifically steering guides These come with the same features as the displacement guides that we are well known for. These are especially for applications where you have a very long entry span into the into the web guide, for example when you're coming off an oven and you need an application right after the oven, The steering guides come with the same linear displacement actuators and they also come with the air SCU5 sensor control unit which is the brain of the web guide and then also with the ARIS WPS web position sensors which come in sensing width of 48 mm up to 221 mm. Our steering web guides come with either grooved rollers or smooth rollers.

Now we recommend the grooved rollers if you're running webs at very high speeds, therefore allowing you to eliminate the entrapped air between the web material and the surface of the roller and eliminating any slippage. With these web guides you can edge guide, center guide, and additionally contrast and line guide using our white light contrast sensors You can actually guide any type of material with no need for calibration of the sensors and it's a very easy to install and operate system. We are Roll-2-Roll Technologies and and you can talk to our experts by contacting us through our website www.r2r-tech.com

---

# Displacement Guide Installation Mistakes

URL: https://r2r.tech/videos/displacement-guide-installation-mistakes.md

Optimizing Sensor Placement and Roller Position in Displacement Guides

This episode is part of the 'Web Guiding Fundamentals' webinar series, focusing on the importance of sensor placement and the location of entry and exit rollers to maintain a 90-degree wrap for optimal control and stability of a displacement guide system. The video discusses how to position sensors close to the exit roller, the effects of web speed on sensor placement, and the consequences of incorrect installation, including bending and oversteering. By following these guidelines, you can ensure smooth operation and avoid unintended consequences like web breaks.

00:00 Introduction to Sensor Placement
00:10 Impact of Sensor Distance on Control Systems
00:23 Effects of Web Speed on Sensor Placement
00:39 Consequences of Incorrect Sensor Installation
01:04 Importance of 90 Degree Wrap
01:16 Avoiding Bending and Distortions
01:32 Oversteering Due to Spread Out Exit Span
01:43 Ideal Sensor Placement Scenario

## Transcript

[Music] We don't want to install the sensor too far away or in the next span. This is mainly for control system purposes and stability. When the web guide makes a corrective action, that action is not seen at the sensor immediately. So, if you're running really fast, you might get away with moving these sensors a little further down.

But if you're running slow, whenever this web guide moves here, you would see that motion, if the sensor is as close to the exit roller as possible. If you install it here or here, especially when the web stops and there is a small error, the web guide would keep moving and that might cause the web to break or have unintended consequences. So, we don't want to have the sensor further away or in next span. And we don't even we don't also want to have a scenario where you have an angle that is not 90°.

If you have a 90° wrap, you have twist. As soon as you introduce something which is deviating more from the 90°, you start creating bending in the web. So these kind of bending is going to act as under steering the web. It's going to cause bending that's going to under steer the web and it also causes distortions and guiding stability.

So we don't really want to have any of these conditions. On the contrary, if you have a span exit span that is spread out like this, this is going to over steer the web. It's the bending effect that is causing that and we really don't want to do that. So ideal scenario would be to have a 90°ree wrap in and out.

[Music]

---

# Do the sensors from Roll-2-Roll Technologies require calibration? 

URL: https://r2r.tech/videos/do-sensors-roll-2-roll-technologies-require-calibration.md

We are often asked how to calibrate our sensors. This video will show that you don't need to calibrate our sensor.

## Transcript

Hi, this is Pedro Velasco with Roll-2-Roll Technologies We want to answer one of the questions that reader in e-news sent us. His question was literally just how do you calibrate your sensors and one of the things we do with Roll-2-Roll Technologies with what we have developed It's that you have to, you don't need to do any calibration of our sensors. Right here today I'm going to do a very short demo using one of our demo units plus two of our main sensors, the 48 millimeters White light sensor to use for contrast sensing and edge sensing and then our white 221 millimeter sensors infrared which we use for edge detection but also for measuring width and center guiding. So let us show you how.

In this case you notice immediately as soon as I plug it in the sensor came on with no need of any other procedure in just coming you know. Now as you can see right now on the screen the sensor I have to go and tell it find the sensor It's searching and then as soon as I put the material It detects where the sensor is at. As you can see it's actually detecting the material as it goes through Ok so now let's say that I want to change the sensor for some other reason and now all [I] do is just unplug the sensor And as soon as I unplug it the display tells us that there's no sensor there and at the same time I'm going to plug in one of our featured sensors the 221 millimeter sensor which has many capabilities like for example We can do edge detection, it can do width sensing and immediately it detects a sensor there. However I'm going to do a search sensor and the same procedure and as soon as I put material it detects the material.

Now it is only guiding off on the edge of the material on the leading edge. That is how simple it is Change Sensors and as you can see there's no need for calibration We hope that this video has helped you understand a little bit more about our about our technology And we will continue to show more stuff, but especially the features that are sensors have. Thank you.

---

# Dusenbery Slitter at ICE USA 2019

URL: https://r2r.tech/videos/dusenbery-slitter-ice-usa-2019.md

Roll-2-Roll Technologies Unwind Web Guiding System at ICE USA 2019 on the Masterslit DC2 by Dusenbery Converting Systems, a division of Parkinson Technologies.

## Transcript

we are at the booth of party so technologies that is USA 2019 in Louisville Kentucky to highlight the loafer all technologies unwind web guiding application the web guiding system is installed on a DC to master Swift like Dusenberry converting systems which is a division of parkinson technologies the feature unwind web guide is composed of a controller a sensor motor driver and actuator the controller is an su v MC e d with ethernet communication option the sensor is the WPS 48 IR and this is in particular can work with anything it provides a forty eight millimeter sensing window for educating and many other applications for web guiding and monitoring with Allen as mentioned before the system will up convert us to work with any material ok transparent forests and non-ferrous without the new calibration you

---

# Efficient Flag Detection Using SCU6x Controllers with ODC Sensors

URL: https://r2r.tech/videos/efficient-flag-detection-using-scu6x-controllers-odc-sensors.md

In this demonstration, we showcase the flag detection capabilities of Roll-2-Roll Technologies' SCU6x Controllers combined with ODC Sensors. The setup includes both unwinding and rewinding mechanisms, with a sensor monitoring the edges of the web. The SCU6x Controller is configured to detect flags effectively, ensuring accurate monitoring even with web oscillation. The video highlights the ease of setting up the system, the parameters involved, and the robust nature of the algorithm, making it a reliable solution for web handling applications.

00:00 Introduction to the Demo Setup
00:40 Setting Up Flag Detection
02:06 Configuring Flag Detection Parameters
04:34 Running the Flag Detection
05:44 Advanced Features and Robustness
 

## Transcript

So what we have set up here in this um demo test setup is um we have an unwind and a rewind. We have added some um flags. Uh there are some flags on the left edge. There are some flags on the right hedge, right edge of the web.

We have a single sensor right here that is looking at the web. And then we do have an SEU6X controller that is set up uh for this flag detection application. So this is the same controller that we looked at in u previous videos. Um I'm going to just quickly walk through how we can set this up for flag detection.

As you can see, we have the um uh sensor one connected. So and it's been set up to center mode because we have a wide enough sensor that can see both edges of the web. And uh um in order to do the flag detection, we're going to go into the tools icon operator on the top right and then the flag detection. So this is the screen where if you are using this just for flag detection applications, then you can be on this screen and monitor it.

But you can set this up, an operator can set this up and you don't have to be on this screen for the flag detection to work. So there are a few things here. Uh just like the home screen, you see a realtime uh preview of where the image is. And since our sensor is looking at both edges of the web, you also see the center line position right there.

Um and then when the flag detection is running, let's say there is a flag, then this flag detect signal would come in. So just to illustrate that, I'm going to artificially create a flag right there. And you can see that the flag detection signal lights on. uh the the duration for which the flag detection is on is called the hold period.

So you can set up all of these. So I'll go in and show you how we can set that up. If you hit the tools icon there, then it's going to bring into this screen. And this is basically where we define certain things.

So what is the minimum length of the flag? Uh when we say length, it's basically how much um uh in distance is it protruding from the edge of the web. So this is in the cross machine direction length. That's what we are talking about.

So if the edge position is in a certain location, how much more is the minimum flag length? Right now we have set it up to 5 mm which is pretty small. Uh depending upon what your application is. Typically for our customers uh it's anywhere from 25 mm which is an inch all the way up to 2 in.

Um but you can set up whatever length you want. And this just means that if the web moves suddenly within this length um or this uh length in the w um cross dimension, it will not trigger a flag. So um the reset duration is basically uh allowing the uh the controller to automatically adapt to wid changes. So if you have a machine running and then you do a on the-fly wid change then instead of um you coming back here and saying hey the new web position is this new location because the width changed uh you can actually set up a reset time.

Essentially that means that for this amount of time if that web position is in this new location we're going to say that that's the new web location. So typically you can set it up anywhere from 5 to 10 seconds. So we'll set it up at 5 seconds. And then hold output.

This is um essentially for um you to take the signal into your PLC. Uh whenever a flag is detected, we output a signal. How long do you want to keep that signal on? That's essentially the hold output duration.

So we will typically set it to 1 or 2 seconds. This really depends upon your PLC and uh if you have a high speed data acquisition system or not. Uh but if you increase the whole time, it just means that uh you guarantee that your PLC is fast enough to see that. So that's essentially it.

That's all the parameters that we have for this. And um if we are now running the machine um we would see that it will start picking up the flag. As you can see there's a flag coming up right now. As the flag goes through um the stack light gets triggered and the stack light is on for the duration that you set so that your PLC can miss it.

So this flag right now that went through was just on the left edge. Here's now on the right edge. You can see that it's picking that up. Just to show you how that works on the controller screen.

Um you have this same kind of an output. When the uh flag comes through, it gets triggered. And um when there's no flag, it's out. And then when the flag comes through, it gets triggered.

You don't necessarily have to be on this screen. Like I mentioned, you can be on a different screen. And this will still trigger the output because that's running in the background. Uh that's essentially it uh in terms of uh uh flag detection.

So just to give you an idea about how robust this algorithm is, we can even set it up to oscillate the web and it will disregard the oscillation and still detect the flag. So I'm going to do that. So now the web is oscillating back and forth. As you can see it's moving.

The flag detection is not getting triggered. When the flag comes through it gets triggered. As simple as that you can have flutter. You can see that the web plane changes quite a bit.

Even then the flag doesn't get triggered. Only when a flag comes through the stack light gets triggered. So just a pretty robust way to detect a flag. Um and you can see that um whether it's left edge, right edge, the sensor automatically knows which edge it is and it detects the flag and provides an output.

So again, Roll to Roll Technologies, we are here to provide you with solutions that are simple to use, robust. Uh we do the research so that you don't have to spend time on trying to um make the machine run just like how you want it to run. uh we do all the heavy lifting so that it's even an operator can set this up and it it doesn't take that much time for you to get this up and running. Um hope you like this video.

If so, make sure to uh like and subscribe to our channel and uh stay tuned for more videos. Thank you.

---

# Effortless Setup: Exploring the SCU6x Plug and Play Operation

URL: https://r2r.tech/videos/effortless-setup-exploring-scu6x-plug-and-play-operation.md

Exploring the SCU6x Plug and Play Operation. Understanding Plug and Play with Roll-2-Roll's SCU6x Controller Join Pedro Velasco from Roll-2-Roll Technologies as he demonstrates the simplicity of their 'plug and play' SCU6x controller, ODC48 sensor, and actuator system. This video covers the setup process, including how to properly connect and power the components using industry-standard connectors. Pedro explains the function of the ODC family sensors, highlighting their ability to detect various materials without the need for calibration. Experience the seamless operation of the web position tracking on the controller screen and learn safety tips for handling the components. Discover how Roll-2-Roll's innovative web guiding and monitoring systems offer unparalleled ease of use and efficiency. Subscribe for more detailed instructional and product videos, and visit our website for further inquiries.

00:00 Introduction to Roll-2-Roll Technologies 00:08 Understanding Plug and Play 00:20 Setting Up the SCU6x Controller 00:53 Connecting Components 01:31 System Ready and Sensor Options 02:34 Demonstrating Sensor and Actuator Interaction 03:36 Safety Precautions 03:49 Conclusion and Additional Resources 04:02 Subscribe and Contact Information

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# Exploring the Dual Rail Power Supply Feature of the SCU6x Controller

URL: https://r2r.tech/videos/exploring-dual-rail-power-supply-feature-scu6x-controller.md

## Exploring the Dual Rail Power Supply Feature of the SCU6x Controller

In this video, we delve into the dual rail power supply feature of the SCU6x Controller. This feature provides a separate power rail for the driver and the logic, enhancing safety by allowing the power to the driver part to be cut off when necessary, such as during access to a web guide. Demonstrations include how to indicate power status and control the actuator via this dual rail system. Applicable to SCU6x controllers with firmware version 4.2 or higher, this functionality ensures added safety for operations.

00:00 Introduction to Role to Role Technologies
00:07 Overview of SCU Six X Controller Features
00:11 Understanding Dual Rail Power Supply
00:28 Safety Benefits of Dual Rail Power Supply
01:18 Demonstration of Power Supply Control
01:58 Technical Specifications and Compatibility
03:03 Conclusion and Final Remarks

## Transcript

hello everyone this is Arin sadri from Roll to roll Technologies today we're going to talk about a couple of different features that we have we're going to see one of the features of the seu 6X controller wherein we can have a dual rail power supply this means you have one rail of power supply for the driver and one rail of power supply for the logic or the controller the main reason why somebody would have this is in the cases of safety so let's say you have a web guide inside a guard door and you don't want the web guide to move when the car door is open or somebody is accessing the machine close to the web guide we can cut off the power supply to the driver part this is mainly for safety reasons if you're familiar with our SCU 5 controller you would know that this particular motor icon would be r in that case any seu 6 firmware version more than 4.2 will have this power indicator so this green power indicates that there is power to the drive the power to the logic is powering the display itself so now I can move the actuator back and forth and you can see that the actuator is moving and if you want to cut off the power supply to the drive I can do that I have a switch here that would cut off and now the power is cut off to the actuator and that's indicated by red and now if I try to move the actuator I won't be able to move the actuator and as soon as the power is turn back on and you get that green signal there and the power is on now I should be able to move the actuator so that's essentially it this is the feature where you have the dual rail power supply that allows you to turn off and on the second rail which is the driver rail in the SCU 6X mxd controller we do have the option where we have a separate Port that powers that which is a 48 volts DC power supply again we can do the same functionality there if the power is cut off to that rail then we would be able to see that indication on the screen this dual rail power supply feature is only available on the seu 6X controllers with firmer version 4.2 or higher this means that there are some older hardware and older firmware where you won't be able to see that feature or you won't be able to have that same functionality in those cases you can still use the second rail to turn off power and turn it back on the only caveat to that is there is no IND indication of whether the power is there or not so all of this features available any controller with the firmware version 4.2 or higher and both for sc6x MD and sc6x mhd

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# Finding IP Address of our sensors and controllers

URL: https://r2r.tech/videos/finding-ip-address-our-sensors-and-controllers.md

Do you need to find the IP Address of the SCU5 controller? See our video to learn how the IP address can be found.

## Transcript

Hi this is Pedro Velasco from Roll-2-Roll Technologies. Today we want to show you how to find the IP address for ARIS sensors or web guide controls are equipped with the Ethernet IP connectivity option. As an example today we're going to use the WPS 440 IR which is a most recent additions to the ARIS WPS sensor lines and this one has an inner router to access the network so that we can monitor this later on. So first we're going to connect an ethernet cable to the M12 connector which is on the side port of the ARIS the WPS 440 IR and then the other side of the connector we're going to connect it to the router in the rj45 Ethernet connector jack Once it is connected, then we go ahead and connect the power to the sensor and then we verify that the connection is correct by looking at the blinking light on the router.

Now after this has been achieved then we can go ahead and proceed to a computer to actually go and find out the IP address for this particular sensor. So by default the router will assign an IP address to the device and this will be a dynamic IP address. Now to find the address you will need to access the Internet through any computer from which you will monitor the device in this case we searched online for Anybus.com and then we look at the support so we hit the support tab. Then we go to the selected product icon and from the select your product Icon you go to the Anybus IC icon and you click on it.

Then you go to the Ethernet IP and here you have a list of software so you're going to download on the software section when the one that says IP configuration utility for module TCP IP configuration. Now you go through the whole process of downloading the this software but once you download then you hit your Start button on your screen and just go to the HMS as you see here and open that up and then you see the IP configuration. When you click on it, it will automatically open this this window right here. Of course, sometimes when you're doing the first time this will not show up so you hit scan and it will scan for anything, any IP addresses are available.

So in this case here you have access to your IP address. Ok, so let's say for example you want, this is a dynamic address, but you want to establish a static address so all you have to do is just right click on the on the line and then you see the configuration tab. Just hit configuration and then you can actually set your static IP address on this window right here. So we mentioned before how to find an IP address for one of our sensors or web guide controls.

It's a very simple procedure as we showed and we hope that this can be of help to you when you are using our products on your operations so again thank you very much and just keep on looking for other videos. Thank you

---

# Frequency Response of Compact Web Guiding System 

URL: https://r2r.tech/videos/frequency-response-compact-web-guiding-system.md

Roll-2-Roll Technologies provides you a closer look to the frequency response performance of our compact web guiding system from 1 Hz to 9 Hz. 

## Transcript

ARIS is an intelligent guiding system that uses a revolutionary fiber optic sensing technology technology to actually measure and control what position this video gives you a closer look to their frequency response performance of our 254 mm web guide from 1 hz to 9 hz. We have a whitepaper on our website that gives more details about the frequency response information. You can find a link for more information in our description below.

---

# Guide Structures of Terminal Web Guides

URL: https://r2r.tech/videos/guide-structures-terminal-web-guides.md

Join us in this informative episode of our 'Web Guiding Fundamentals' webinar as we delve into the intricacies of guides structures of terminal web guides, otherwise known as unwind and rewind web guides. Learn about the various components, including the role of actuators and sensors, the design considerations for mechanical rigidity, and the importance of actuator sizing. Gain insights into the differences between guiding and chasing the web, and understand the advantages and disadvantages of these systems. This episode is essential for anyone looking to enhance their knowledge of web handling solutions and improve their web guiding performance.

00:00 Introduction to Web Guide Components
00:12 Unwind Web Guide Structure
02:03 Rewind Web Guide Structure
03:36 Design Considerations for Web Guides
05:08 Installation and Performance Considerations
05:23 Advantages and Disadvantages of Web Guides

## Transcript

So let's dive into detail about different components of the web guide. First we'll start off with guide structures and look at how guide structures are with different types of web guides that we saw. So first and foremost we have the unwind web guide structure. In this case you have a parent roll feeding the web into your machine.

This role is on a shifting stand or a base supported by linear bearings. An actuator connects the moving stand with the fixed base and then there's a sensor here that is looking at the position of the web. The main objective of an unwind web guide is to ensure that the web fed into the process is at the desired location. Because of that, you have a sensor fixed to a machine frame actually moves in and out of the monitor.

It's going to go in and out. And the feedback from the sensor is used to make this unwind guide move in and out so that it can position at the right location. One thing I wanted to point out is that there is a shifting idler. When I say shifting idler, it means that this idler is attached to this moving base.

The main reason why we do that is that if we put a sensor right here, it is not an ideal location just because of the fact that when the diameter of this roller changes, you're going to have the web plane go in and out. And if that happens, that's going to affect your guiding. Typically, you would see a shifting idler. It doesn't have to be one.

It can be multiple. It could also be a whole frame with a lot of rollers. We need to put the sensor just downstream of the last shifting idler and the sensor is fixed to the machine frame so we can guide the web. So those are the main things with an unwind guide.

Now when we look at rewind guide rewind even though we call it as a guiding it's not actually guiding the web it's chasing the web. The main thing unique about this is that in a rewind system you have a sensor attached to the rewind frame. All of the things in terms of the carriage it's exactly the same. You have a sensor that is attached to the rewind stand so that when the rewind moves, the sensor also moves and then you have a fixed idler.

Rewind is not really guiding the web. It's actually chasing the web. And the main reason why we do that is that we need to maintain the relative position of the web and the rewind roll. If we put the sensor on a fixed frame and look at this rewind roll, then we would not know the relative position between those two.

That's the main reason why we attach this sensor onto the moving rewind stand gives us indirectly the position of the rewind stand. And the objective is to make sure that we move the rewind stand so that the middle of the sensor or the guide point of the sensor matches the location of the web. Like I mentioned, it's not really guiding the web. We are chasing the web so that the rewind roll would be at the right location to get the web bound properly.

So just to summarize about these two terminal guides, we can look at what are the things that we need to have a good rewind or unwind guiding system. First of all, in terms of design, we need to make sure that the mechanical structure and rigidity and stiffness are designed properly. We are moving a big mass and depending upon the type of web may be metals it may be thousands of pounds multiple thousands of pounds that we are trying to move and we need to make sure that the structure is rigid enough so that we can avoid any mechanical resonance the natural frequency of the structure should be at least 3 to four times the operating frequency of the control system. The other thing we need to consider especially with these kind of guides is that we need to size the actuator properly.

When we talk about sizing the actuator what we are talking about is it should have enough thrust so that it can push the mass. It has enough thrust to overcome the static friction and provide the desired acceleration to reject the disturbances or errors that may be there. Just like the mechanical structure rigidity, we need to also make sure that the actuator coupling and the actuator stiffness are all accounted for. Any play in the actuator coupling is going to reduce the stiffness of the overall system.

That's going to destabilize your system. In terms of installation consideration, the main thing that we want to look for in these type of guides is the location of the sensor with respect to the moving stand. Either it's fixed to the machine frame or it's moving with the carriage. That's the main thing.

These web guides are simple. That's one of the advantages of these web guides. And these web guides really do not have to take advantage of the normal entry roll because all the rollers are parallel to each other. So there's not going to be any misalignment in them.

So there's going to be less amount of stresses on the web. The disadvantages with these kind of web guides. Well, first of all, you need a high thrust actuator, especially when you have larger mass to move and it's not cost effective. If you really want good performance from a web guide, if you want to reject a high frequency disturbance, then this may not be a good choice for us.

[Music]

---

# How Accurate can you Guide a Web?

URL: https://r2r.tech/videos/how-accurate-can-you-guide-web.md

In this webinar episode on web guiding fundamentals, we delve into the accuracy of web guides, discussing various factors that affect their performance. We explore how steady state and transient errors can influence guiding accuracy and highlight the importance of machine quality, material properties, and proper installation. Additionally, we cover the design requirements necessary for achieving optimal web guide performance, emphasizing the need to understand conditions like web speed, thickness, and tension.

00:00 Introduction to Web Guide Accuracy
00:19 Factors Affecting Steady State Error
00:51 Challenges with Transient Errors
01:33 Impact of Wrinkles and Other Issues
02:30 Design Requirements for Optimal Performance
03:00 Conclusion and Summary

 

## Transcript

[Music] So the final question here is that you have a web guide and we talked about all these different things. What is the accuracy or how accurately can you guide a web? It actually depends. Like I mentioned, there are lots of different parameters that are going to affect the accuracy of the web guide.

If we are just dealing with a steady state error, we can expect plus or minus 0.25 mm. If you have a good machine in a perfect material, this is what you can expect. Higher accuracies are possible. Like in printed electronics, you can get much higher accuracy.

But if we're dealing with steady state errors, you have a good edge and all those kind of things, this is possible. But the problem is that most web guides are going to come into transient errors. These are either disturbances or material properties that are going to affect the disturbance in the web guide. Now, if you're trying to correct a transient error, it really depends upon what is the magnitude of the error, what is the frequency of the error and so on.

And another important thing that we need to consider is that these transient errors can actually propagate downstream of the sensor and these are called what are called as wave generation. Even though you correct it at the sensor, you don't really know the angle at which the web is approaching and that can cause weaves downstream. You won't have good guiding performance if you have wrinkles. I mean, if the web is wrinkling, that is going to cause the edge to move back and forth.

There's no way you can have good guiding performance with that. Or edge curl, flutter, or sometimes plane change can also have that effect. If you have large magnitude error and your stroke of the actuator is limited or the correction that the webgate can provide is limited then you can expect good grading performance whenever the actuator tops out on either side of its stroke. If you use a lower bandwidth actuator and you have a higher frequency error, you can expect good guiding performances and sensor.

If you don't have a good sensor or if it has gain changes then you can expect a good guiding performance and then improper installation can actually amplify the error. So that's another thing that we can expect. Anyway, so just to summarize the factors affecting we talked about a machine related, process related, material related and the web guide related which is like the stroke deadband actuator backlash correction stroke limit and things like that. So in terms of design requirements uh a good knowledge of the the the conditions like web speed location thickness stiffness environment tension side correction all of these are important for us to have a welldesigned web guide.

If you have a good understanding of all of these, we will do well. [Music]

---

# How to - One Time Calibration of the SCU6x Controller for Multiple Width Measurement Application 

URL: https://r2r.tech/videos/how-one-time-calibration-scu6x-controller-multiple-width-measurement-application.md

SCU6x Controller Calibration for Precision Width Monitoring

In this video, Aravind Seshadri from Roll-2-Roll Technologies walks through the one-time calibration procedure for the SCU6x Controller, essential for precise width monitoring. This calibration adjusts for conditions like sensor placement and lighting variations, ensuring high-resolution measurements. While not necessary for broader tolerances, this detailed procedure is crucial for high-precision applications. Operations in the automotive and medical industries, where quality control is paramount, can particularly benefit from this feature. Specific benefits for slitter rewinder processes include continuous, accurate width monitoring without the need for intermittent sampling, enhancing overall efficiency.

00:00 Introduction to Calibration Procedure
00:14 Understanding the Need for Calibration
01:11 Calibration Process Explained
01:48 Practical Calibration Example
02:50 Batch Calibration for Multiple Samples
03:41 Real-World Application and Benefits
05:00 Conclusion and Final Thoughts

## Transcript

One other thing we need to do whenever we are initially setting up is um onetime calibration procedure that can be done on this screen. The idea for this is that we have the ability to calibrate our sensor for your conditions. We do have a calibration done in the factory, but when it's being installed, the sensor might be installed at a different distance than what we typically expect. And there are other things with the lighting and contrast that might change some of these parameters.

So, this calibration is necessary only if you're looking for a higher resolution measurement. For example, if you're looking for a tolerance of plus or - 1/16th of an inch, you don't need to do any of these calibration things. But any anytime you are below that. So anytime you're below a millimeter or below a 1/16th of an inch resolution, you would need to do a calibration.

This is done just for that particular setup. Once you do it, you don't have to do it for the rest of the run. It'll be stored and you take that calibration value. What does the calibration do?

Essentially, I have a material or a sample of a known width and the sensor is providing a raw measurement. We're going to compare those two and then say the calibrated measurement is based on the actual sample width and whatever the raw offset is, that's the correction we are going to use for the rest of the measurements. So that's indicated here. So that's basically saying what is the correction from the actual width to the measured width.

That's essentially what the calibration is. So it's just creating a offset. So for example, let's say the sample width is 46. To change that, you press whatever you need to increment by and change that value.

I am going to put that as 49.244. Right now it's measuring 49.293. If I want to teach this, my sample width should match my measured width. To do that, press this teach icon and then press accept.

Now it has applied a correction. Essentially the raw width plus this correction gives me my actual width. And that's pretty simple. It's just a regular bias or correction that we are adding.

Nothing fancy about this calibration. So you can do that for all these other materials. We don't necessarily need to do this if your tolerance is 1/16th of an inch or 1.5 mm. We don't need to do that.

But for some customers looking for a higher resolution, you do that calibration procedure. Now, just to make it simple, you can enter all of these sample widths already and then you can do a one-time teaching. Let me show you how that works. I'm going to enter this sample width here.

Okay. So, if I want to do all of them together, I'm going to press this teach all button. Make sure that it's highlighted. And then I'm going to press this teach and accept.

Now, all these samples will have a correction. Before we had everything as zero. And if I now scroll through web five, web 4, web three, web two, and web 1, all of them now have a correction. So it's just a quick way for you to do this.

The general use case for this is that let's say you are a customer in automotive or medical and you have a QC process where you are only sampling a part of your product. You are setting up your slitter. You pull the initial sample after the operator has set up the slitter and you take that sample and you're doing a QC on that. Now, essentially what you're going to do is take that sample and enter it like what I have here.

Then you're going to do a teach all. Once that is done during any part of the run, we are taking that measurement online in line 100% of the time. So that's the biggest advantage with this system. In your typical process right now, you might be doing one sample at the beginning of the run.

At the end of the run, the operator needs to stop the machine, take that sample, give it to QC, take the measurement, and then everything is good. You run it, and then every time the machine is stopped, there is another sample that is taken. So, this is a random sampling process with a lot of time involved between one run to another. and we completely eliminate that and allow you to keep running the machine and monitor the width all the time.

So that's the biggest value proposition with our system. And that's essentially it. So that will allow you to calibrate each of these samples and be done with it.

---

# How to Access the Operator Width Measurement and Monitoring Screen on the SCU6x Controller

URL: https://r2r.tech/videos/how-access-operator-width-measurement-and-monitoring-screen-scu6x-controller.md

Accessing the operator width measurement and monitoring screen from the home screen is a simple task to perform. In this brief video, we guide you through the steps necessary to set your SCU6x Controller for web width measurement and monitoring. Start by pressing the tools icon, followed by the operator icon located at the top right, and then the width icon. You'll first arrive at the operator width home screen, and there's an additional setup screen available where you can perform further setup tasks.

 00:00 Accessing the Operator Width Screen

00:17 Operator Width Home Screen Overview

00:21 Additional Setup Screen

## Transcript

To get to the operator width screen from the home screen, we're going to press the tools icon, then the operator icon on the top right and then the width icon. This first page is the operator width home screen. The second page is an additional setup screen where you're able to do more setup related things.

---

# How to Access the Operator Width Screen on the SCU6x Controller

URL: https://r2r.tech/videos/how-access-operator-width-screen-scu6x-controller.md

How to Access the Operator Width Screen

In this video, we guide you through the steps to access the operator width screen from the home screen. Start by pressing the tools icon, followed by the operator icon located at the top right, and then the width icon. You'll first arrive at the operator width home screen, and there's an additional setup screen available where you can perform further setup tasks.

00:00 Accessing the Operator Width Screen
00:17 Operator Width Home Screen Overview
00:21 Additional Setup Screen

## Transcript

To get to the operator width screen from the home screen, we're going to press the tools icon, then the operator icon on the top right and then the width icon. This first page is the operator width home screen. The second page is an additional setup screen where you're able to do more setup related things.

---

# How to Add SCU5 Controller to PROFINET System

URL: https://r2r.tech/videos/how-add-scu5-controller-profinet-system.md

This video shows how to import SCU5 controller as a device into PROFINET ecosystem with GSDML file.



The different versions of the GDSML files based on the ethernet module are available on our website here:



👉🏻 PROFINET GSDML File for SCU5 firmware Version 3.5+ using Hilscher Module: 🔗[https://r2r.tech/documentation/profinet-gsdml-file-scu5-firmware-version-35-using-hilscher-module](https://r2r.tech/documentation/profinet-gsdml-file-scu5-firmware-version-35-using-hilscher-module)



👉🏻 PROFINET GSDML File for SCU5 firmware Version 3.5+ using HMS Module: 🔗[https://r2r.tech/documentation/profinet-gsdml-file-scu5-firmware-version-35-using-hms-module](https://r2r.tech/documentation/profinet-gsdml-file-scu5-firmware-version-35-using-hms-module)



For more information about the SCU5 controller please visit: https://r2r.tech/products/roll-2-roll-controller.

## Transcript

hello everyone in this video we're going to look at how we can configure our sg5 controller with the profinet industrial Internet Protocol on it with a profinet controller we don't have a profinet controller here but we're going to use a profinet Master stimulator to show how we can add our scu5 controller to a profinet controller using the HTML file I have a controller here and this is with a profinet industrial Internet Protocol the way we can check what industrial ethernet protocol we have is to go into tools and then hit the power user communication and then other shows that we have a profinet device and then we also support a couple of different vendors for these industrial ethernet protocols one is hillshare and then the other one is HMS essentially the configuration for either of them are exactly the same except that for hillshare you need the right heel share files and then for HMS you need the right HMS files support files the gdsml file now that we know what module we have we can go to our website and see how we can get that information so if you go to our website r2r.tech and then go to resources and documentation within this menu we're going to click on the support files and it shows up a variety of support files that we have today we're going to look at how to add the profinet so we're going to look at the profinet esdml file like I said we have two different modules one is hillshare and the other one is HMS the the steps are exactly the same but we just need to make sure to download The Right files so in this case it's hillshare I'm going to right click on that and then say save linkcast and then put it in a location where you can pick it up so that's I'm going to save it once this is done then in our case we're going to show how we can do it with a master simulator but in your specific application you're going to use that specific controller software maybe Tia portal or S7 whatever the programming language for S7 is for the Siemens you're going to use that to import it so we'll show how we will do it with the um Master simulator okay we're going to open Master Simulator the profinet master simulator if you have multiple network cards you might have to choose the network card that you have but in our case we don't have multiple network cards so we're just going to select that and then we can start looking for the device once you open that it's going to automatically pull up that interface search the network for the profinet device just to confirm that this is our device you see the MAC address of the device and if you go back to our controller and you can see the MAC address and it ends in 83 and that's exactly what we see on the computer as well we can give whatever name we want for this so we're going to give a name and then with the profinet the network actually sets the IP address for the controller so what we're going to do is we're going to go ahead and set that so in our case we're going to set the IP address for our controller from this program so I'm going to set it as 192. 168 one I'm going to give maybe 103 as the IP address subnet is 255 255 255 0. and then the Gateway is 192 168 1.1 and then I'm going to apply that and it will update that IP address and all the network information so once we do that then we have set the IP address of the controller from the from this profinet master and we're good to go obviously right now you can see that it's not connected that's because we want to make sure that we're able to configure that in order to configure that device you do need that gsdml file and I'm going to go in and open that file from the location that I downloaded and the main thing for this when we import the GDs ddsml file is that we actually need to set a few things and one of the first things is that the actual device that is connected and that is available in dim 17 nic-52re this is what we want to look for so we're going to select that device access point as dim 17. and then we need to set the input and the output from from our controller properly so we have 32 input bytes so we're going to select 32 input bytes and the input can be put any of these slots either 5 or 8 so I'm going to select five and set that input 32 bytes to slot 5.

and then the output is actually 16 bytes and so I'm going to select 16 bytes as the output and then the output can be selected in slot 1 or Slot 4 so I'm going to select it to slot 4. and that's about it and then I can apply now once this is done I can click on the start and now it's going to bring up the device and basically we can see the i o data input is actually the output from our su5 controller and then the output that you see here is actually the input to the scu5 controller and you can see that the connection state is there it's established it says the MAC address on our device also if we have some some data coming in you can see that on both on the controller and the device if I have some my finger in front of the sensor you can see that the data is updating so that's essentially the way in which we can import the scu5 controller into the profinet ecosystem using the gdsml file the steps are exactly the same for for either the HMS or the Hillshire only that we need to get the right gdsml gsdml file for that but anyway that concludes our demo on how to import the scu5 controller with the profinet industrial ethernet protocol into a Siemens ecosystem and please subscribe to our channel for more informational videos and we'll see you soon

---

# How to Add SCU5 Controller with EtherCAT to Beckhoff PLC using TwinCAT

URL: https://r2r.tech/videos/how-add-scu5-controller-ethercat-beckhoff-plc-using-twincat.md

This video shows how to import SCU5 controller as a device into EtherCAT with the ECS file.



👉🏻 EtherCAT ECS File for SCU5 firmware Version 3.5+ using Hilscher Module:



🔗[https://r2r.tech/documentation/ethercat-ecs-file-scu5-firmware-version-35-using-hilscher-module](https://r2r.tech/documentation/ethercat-ecs-file-scu5-firmware-version-35-using-hilscher-module)



For more information about the SCU5 controller please visit: [https://r2r.tech/products/roll-2-roll-controller](https://r2r.tech/products/roll-2-roll-controller).

## Transcript

hi this is Carlo from Roll to roll Technologies and in this video I'm gonna show you how to add a su-5 controller into a backoff automation system with green cards here is my setup I have my industrial PC over here where I set the one of the parts to be either cut master and I connected this industrial PC directly to my su-5 over here and I can see into the settings in the communication setting I have a either cut version of the su-5 and because it's a either system I don't have IP address of setup mask or Gateway I will only have the Mac address over here first step we were gonna head to our website r2r.tech and download the ESI file for the su5 I'm gonna go into resources documentation and then support file and I'm gonna look for the ethercat file I'm gonna do right click and save link as and I'm gonna choose the directory when I want to save my file and do save and gonna go file was saved now I have to copy this file into the proper directory so I'm gonna copy this and go PC twin cut 3.1 this is my version configuration config IO either cut and I will pass that in this directory then I'm gonna go and Open my cut software and I will go into twin cut ER cut devices and do reload device description at this point there are two ways to add the SEO 5 to your io3 one way is to go over here in your either Cuts Master right click and do scan with scan for new devices and here I have the roll to roll device by doing this procedure you will have all the register a very descriptive name but just with the register number we this is a way to do it but we will suggest to add it by using the ESI file that we just downloaded so you will go here into your ethercat master and add a new item search for the role to roll technology category and add the su-5 by doing so you will have variable there are much more descriptive but for the input and for the output and now once we have done this if you do go back to the internet eater Cuts master and do the scan it will recognize the device and if you toggle this button to show online data you can go in and verify that the connection is present for example if I look at the left edge of the sensor and do the online data when I pass something in front of the sensor the listening become bit I see the data updating the show me that I have a good connection to the SEO 5 and then you can link the variable to your program and you're good to go and this was all I have for today's video if you are interested to our video subscribe Below have a good day

---

# How to Center Guide with Two Sensors with the SCU6x Controller

URL: https://r2r.tech/videos/how-center-guide-two-sensors-scu6x-controller.md

In this episode, we explore how to utilize the center guiding feature of the SCU6x Controller with two sensors, focusing on automatic adjustments and setup. We demonstrate the mechanics of center guiding using an actuator and explain the importance of using sensors of the same range. With detailed visuals, we show how to reset the guide point and align the material to the center of the machine. Learn about the two primary reasons for using center guiding: managing variable web widths without relocating sensors and improving alignment quality when dealing with irregular material edges. We highlight the benefits of our sensors' broad range, which enhances system adaptability without the need for frequent adjustments.
 

00:00 Introduction to SEO Six X Controller

00:31 Setting Up Sensors for Center Guiding

01:12 How Center Guiding Works

01:54 Advantages of Center Guiding

02:35 Flexibility and Range of Sensors

03:02 Challenges with Older Systems

03:47 Second Reason for Center Guiding

05:01 Resetting the Guide Point

05:41 Guide Point Offset Explanation

## Transcript

So, one of the other things with the SC6X controller is that we can do center guiding with two sensors and it can be done automatically. We talked about how to set up the different sensors for different configurations. So, please take a look at those videos. In this video, we're just going to show you how it works with an actuator, how things look, and how to reset the guide point for center guiding.

What we have is a couple of sensors connected here. One of the things with center guiding is that we would like the two sensors to be of the same range. Even though the system would work when you have two different ranges just on the display to make it simpler and not cause any confusion, it's better to use two sensors of the same range. Right now, I have an infrared sensor and a white light sensor just for illustrative purposes.

In reality, anytime we are doing edge or center guiding based on the edge of the material, we're going to always use an infrared sensor. So, let's go back to the screen and see how it looks. This sensor is set to see the left edge and this sensor is set to see the right edge. So, if I have a material that is presented, you can see that it's seeing the left edge and the right edge.

The green in the middle is showing the center line position. And in this particular case, we got the guide point offset to be zero. So if I set it to automatic, then the actuator is going to move back and forth based on if the center position is within the guide point to the left or to the right. And that's essentially how the center guiding works.

There are two main reasons why somebody would use center guiding. One is if you're changing web widths and you want to align the material to the center of the machine, then center guiding is the best option where you would place two sensors on either side and the those sensors are equidistant from the center line of the machine. So when the web width changes, you don't ever have to move the sensors and it automatically adjusts itself because it's going to look at the left portion of the web seen by the left sensor and the right portion seen by the right sensor. This is one of the common features that we have or common value proposition from our products is that our sensors can go anywhere from 48 mm up to 960 mm.

That means you can have a width change of about 96 mm up to about 1920 mm without needing to move the sensor. This provides a lot of range and flexibility to be able to have a system that can adapt to wick changes on the flight. The older generation systems might have some actuators that move the sensors based on the wick change. And more often than not, what happens is that those actuators have their own control loop that needs to be tuned.

The actuators can wear. These are the actuators for the sensors that could wear over time. And that creates an issue. And then the response time, especially when you do a wid change on the fly with those kind of systems, is going to be much lower than compared to a system with a sensor that is wide enough to cover all the width changes.

So that's one of the main reasons for using center guiding is that you can do different widths without moving the sensors whenever the width changes. The second main reason why you would use center guiding is that let's say you have an edge especially some kind of an extruded edge and the edge quality might not be great. So before it goes into a slitter you you have an edge and the edge is not that great. Instead of aligning to one edge of the web, in that case if you use two sensors and then use the center line position, it takes the average of the left edge and the right edge and does the measurement that is going to be the center line measurement and it's going to guide the web to the center.

This is one of the biggest advantage for using two sensors and doing the center guiding and especially when you have irregular edges, those edges variations are not going to be identical on both sides. This smooths out your edge profile and allows you to guide the web in the middle of the machine and that significantly improves the wound roll quality especially if you don't have a pretty good slit edge. So the advantage is that you are averaging based on two edge measurements and this helps in smoothing out the edge position. Those are the two main reasons why you would use center guide.

One of the other things that I want to show with center guiding is that you can do the reset guide point just like what we did with edge or center guiding with two sensors. Let me show you that. Going back to the screen here, we have the web now and the green position indicates the center line position. If the web is moved that way and for whatever reason you need to do that, you could do the same reset guide point and accept.

Now the guide point offset is there. If the edge position goes on either side, the actuator changes its direction back and forth. This is for doing the center guiding with the point offset. Now, like I said, it's not usual for you to change the guide point offset with center guiding just because you want the material to be aligned to the middle of the machine.

The reason why we allow you to do that is that let's say you had not installed the sensor at the right location to begin with. Instead of going and physically moving the sensor, you could just move the offset. And that's the reason why we allow a guidepoint offset even when we do center guide.

---

# How to Change the IP Address of SCU5 Controller with HMS Module

URL: https://r2r.tech/videos/how-change-ip-address-scu5-controller-hms-module.md

This video shows how we can set the static and dynamic address of the SCU5 controller with the HMS module. This is slightly different from the Hilscher module. For more information about the SCU5 controller please visit: https://r2r.tech/products/roll-2-roll-controller

## Transcript

we looked at how we can change the IP address of the device using our Hill share module in this video we're gonna take a look at how this can be done if you had one of our HMS modules for the ethernet IP so I'm going to switch back to my controller and the tools icon and then power user in the bottom and communication the difference that you're going to see is this this says HMS that tells us that we have a HMS module and in this case whenever we do change from static to Dynamic IP address we're going to turn on the DHCP and press set unlike the hill share module the controller will not power will have to manually power cycle this for this to take effect so we're going to do that by just going to the home screen and then hot unplugging or power cycling the controller so we're manually doing this not doing automatically once we power cycle it then you can again go back into the tools icon power user communication and now it's going to show the IP address of the device the main distinction with the Hillshire and the HMS when you have DHCP turned on is that the HMS module will actually show the IP address the new IP address that is given to this device by the router whereas in the health share these all of these three values are all going to be zeros it'll just show you the MAC address that's the main distinction now if we want to again turn it back into static IP address what we are going to do is set that to off set it refresh it and then we're going to power cycle it again physically we're power cycling it this is just to make sure that the device gets that hcp to be off and then we can go into the tools again power user communication and do the same thing of changing the IP address so we can say 1 92 168.00 one and one zero one and then set refresh when we hit refresh in this module it will go back to the old AP address so that's the reason why with the HMS you do have to manually power cycle it every time so we're going to do that power cycle it and then we actually set the IP address to 101 and once the power cycle is done go into tools power user communication and then the new IP address is 101. now you set the AP address either manually or through DHCP with the two different modules that we have Hill share and HMS whenever we change from one to another with the hill share there will be a power cycle with HMS static or dynamic there won't be a power cycle automatically we have to manually do it and that's the difference in the next videos we'll look at few other things of configuration with the profinet and ethercat but please follow us and subscribe to our channel so that you can take a look at all the informational videos that we provide thank you

---

# How to Connect SCU5 Controller Directly to a Computer via Ethernet

URL: https://r2r.tech/videos/how-connect-scu5-controller-directly-computer-ethernet.md

How to Connect SCU5 Controller Directly to a Computer via Ethernet

## Transcript

okay similar to how we connect the sco5 controller to a computer connected through a network we can also do something where we can directly connect the sco5 controller to a computer there is the M12 to RJ45 ethernet cable that comes that we Supply and the M12 decoded part goes into our su-5 controller and then the RJ45 we can directly connect it to a computer and I'm going to show you how we can do that just to recap again on the controller we just need to make sure that we have we know what the IP address of the device is so go into the tools power and the communication settings we have the IP address what we need to do is we need to set up the computer with the static IP address so that we can connect it through there that's what we're going to show so if we switch back to the computer you can go in and look for ethernet settings and what we are going to do is the RJ45 cable is connected and right now it says unidentified network we're going to go in and say change adapter settings and this is the hardwired network we're going to right click on it properties and then go in and select the Internet Protocol version as tcpip version 4 and then click on properties right now this is set to obtain the IP address automatically so we're going to say to use a static IP address so we just need to set an IP address for this computer so as we saw the IP address for the controller was 192.168.1.100 and then the subnet is shown there and then the Gateway is shown there as long as we pick an IP address that is different than 100 we're good so that's what we're going to do we're going to type in 192 168 1 Dot 105. and then the subnets are automatically generated you don't necessarily need to put a Gateway in but sometimes some programs might create an issue so just to be sure we can put the gateway in as what the Gateway of the controller was and then click OK click close And that's about it just to make sure to check if that IP address is set properly you can just go in and do the same thing ipconfig and so what we are interested in is the ethernet adapter which is the hardwired ethernet so it's showing the IP address as 105 and the Gateway and things like that now we should be able to open the web browser and type in the IP address of our controller 192 168 1.100 and now we can connect to our controller so this is a cable directly from our controller to the computer and this is how simple it is to set it up so that you can have the communication between the controller and a computer thank you for watching please subscribe to our channel for more information about our products and how to use them thank you

---

# How to Connect to the Web Dashboard on the SCU5 Controller

URL: https://r2r.tech/videos/how-connect-web-dashboard-scu5-controller.md

This video show how to launch the web dashboard on the SCU5 controller. This dashboard is enabled by a built-in web server on the SCU5 controller. And the dashboard is only available with the following industrial ethernet protocols:



- EtherNet/IP
- PROFINET
- Modbus/TCP



For more information about SCU5 controller please visit: https://r2r.tech/products/roll-2-roll-controller

## Transcript

hello everyone today we're going to look at how to connect our scu5 controller to a laptop or maybe a computer without the need for any PLC programming we have the ability to connect to our controller and have a quick snapshot of what the sensor is seeing and look at various parameters that are coming out from the controller we call it a web dashboard and this one is available so that anybody trying to planning to use our system with the industrial ethernet output on it they'll have a quick way to prototype and quickly connect our system to to a computer and see that everything is functioning as expected before they start writing the PLC programming that's what we're going to show today how to do it and for that I have a setup here with two sensors in this case we're just going to use One sensor at this time so we got a couple of sensors connected to our controller and here's our controller and then we'll show how we can look at the IP address from this controller and how we can connect it to a computer and we'll show that in a little bit okay so we're going to first set up this controller for the proper app in this case we have Sensor 2 connected and the sensor is actually looking at both edges of the web so we're going to set that up for width measurement application so go in the tools power user sensor and I'm going to disable sensor one and then enable sensor 2. this is a WPS sensor so we're going to toggle that switch as well and then set this to Center mode and another way we have it set for Center mode the next step is to make sure that it's set to width so we're going to go into the analog output and then width as the option and now it should show the web um with the center line and also shows the width of the web now in order for us to make sure that we are able to get this data through Ethernet before we connect to a PLC we can do the quick connection to our web browser in the dashboard and for us to do that we need to make sure that we have the right network setting and then make sure that the computer is connected to the same network so in order to do that go into tools power user communication get the IP address of the device in the subnet and Gateway if we need to change these settings we can just change the settings you can refer to one of our previous videos where we showed that and once that is done what we can do is we can go to the computer and open the web browser at first we need to make sure that the computer is on the same network we can do that by going into the computer settings what I'm going to do is I'm just going to go into control panel and then click on network and then we can click on the the network settings here and in this case we're connected to the Wi-Fi and the Wi-Fi in order to find the IP address for that Network you can go in and type in command prompt and then be config slash all so this particular network is connected to the Wi-Fi is connected to 192.168.1.1 which is the same Gateway that we had connected to in the su5 controller so we're all good all we need to do is to type in the IP address of our controller that's 192 168 1.100. and now you should be able to see the dashboard so the dashboard provides you with the real-time information on what the controller is seeing so you're seeing the width displayed here we have connected to the Sensor 2 and that's what it's showing Sensor 2 Sensor 2 is set in Center mode so both left and right Edge are enabled this particular sensor WPS 112 has got 896 pixels 127 Micron and that's what it's showing here and then it's also providing you a width output right here and the width output is 53.34 millimeters now this dashboard like I said it's just a quick way for us to look at the parameters from the system from the controller and that data that goes into the ethernet we're able to quickly view it and this way we can test the system make sure that it works as it's supposed to work before we even need to start programming anything for example if I go into our controller and oops if I go into the controller and then change some of the settings for example instead of this being in automatic I can put it to freeze and go in here and change the thresholding method and if we put it to static and if you come back to the web dashboard you can see that now the thresholding is static and if I change that to Dynamic then you can see that it automatically changes that to Dynamic the dashboard is just a way for us to see the data it doesn't allow us to set parameters on the controller this is just in Denver for safety purposes but a quick way for us to look at all the information that is coming from the system we also provide an ability to log this information if you are if you want to collect data for some extended period of time and then see how the data looks like you'll be able to download the data and it downloads it into a CSV file and you can look at all the parameters I think there are like 20 or 30 Columns of data that comes in and if you want to set it up to download the data automatically then what you can do is you can just click on this and you can select how often you want to download the data and you can also select how many data points per second do you want to collect for example I can say I want to collect four samples per second and then download the data every 30 minutes and just to show you how that works I'm going to set it to one minute and as soon as one minute expires it's gonna automatically download that data into a file and we can also set up Automatic download options and folders where we can download it this information is just available in your web browser settings and that way you can let the system collect the data automatic at the frequency that you have set and and then you can just come back later and then look at the data and do it so as you saw it just downloaded this next set of data there in the file itself has the date and time and all those information there so you can go back and look at that that's a quick overview of the how to connect to our web dashboard if you have if you are through a network in the next video we're going to see how we can connect it to a computer directly without a network thank you for watching And subscribe to our channel for more informational videos about our product

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# How to Find IP Address of SCU5 Controller with a Hilscher Module while DHCP is Enabled

URL: https://r2r.tech/videos/how-find-ip-address-scu5-controller-hilscher-module-while-dhcp-enabled.md

How to Find IP Address of SCU5 Controller with a Hilscher Module while DHCP is Enabled

## Transcript

hello everyone this is aravind say shadri from Roll to roll Technologies today we're going to talk a little bit about the IP address configurations on our controllers we do provide industrial ethernet option for our scu5 controller and we support multiple different industrial ethernet protocols like ethernet IP profinet ethercat or modbus over TCP but in this video we're just going to look at how we can set the IP address for our controller either doing a static IP address or setting up a dynamic IP address and then how do we find the IP address of the device either through the controller or through the network and then how do you configure the IP address through a network IP address configuration tool that's what we're going to look at today we have our controller set up here in this particular one we have the scu5 controller with Hillshire internet module so you can find the the type of module and the type of controller that we have by going into from the home screen if you just click on tools power user and then communication this brings up the screen where you can see the device configuration so we have an ethernet IP industrial ethernet protocol and there are a couple of vendors that we use for that one of them is Hillshire and the other one is HMS so this one we have a hillshare and it also shows that the ethernet is on the DHCP is off and the FTP is off most of the time we don't need to change any of these settings when it says that the DHCP is off that means that we have the static IP address connected or set for our controller and the controller actually shows what the IP address right now is it's 192 168 1.100. now in case you want to find this IP address through the network our controller is actually connected to a router it can be connected to a router or a switch or anything like that we just want to make sure that if you are connected to a router that the Gateway is set properly for that router's Gateway if you want to Now search for this controller from your computer if you know the IP address of the device you can directly type it in to your web browser and 192 168.1.100 and if you if we have good connection it's going to bring up our dashboard and you can see this but what happens is that sometimes you might not have it set up as a static IP maybe it's a DHCP we'll just go over that and show you if you have a DHCP set how can you find the IP address of this device so I'm going to switch back to my controller if you want to set the IP address to be dynamically generated by your network device all we have to do is that set this DHCP to be on and then press set when we have a hillshare module when whenever we change that configuration it's going to force the controller to power cycle and that's what happened right now it is power cycled and you go into the screen again tools power user communication and it's going to show that the DHCP is on but as you can notice all the IP address subnet Gateway everything was set to zero we do know that there is a module just because of the fact that the MAC address is visible and then the ethernet IP and the hill share these are all visible that tells us that we have the module there but we just don't know what the IP address is if we run into this case we can use a network scanning tool to be able to find the IP address I have this already installed on my computer and I will switch to the computer and show you how we can find an IP address of this device this particular module is a health share module and hillshare has a tool called ethernet device configuration tool and I'm going to click on that it's going to open that up and then I'm going to search for the device and now it actually found the device and it's telling us the IP address of the device and this is our device scu5 you can notice that the IP address didn't change it it remained as 190 to 168 1.100 but again it could change to whatever IP address the network router is going to give you so it may not be the same as the static IP address again if we want to make sure that uh it's it's actually detecting the device over the network but you can also bring up the dashboard and type in 192 168.1.100 and this is going to show you the um the data coming from the device and obviously if we have something in front it's going to update that as well so that's a quick way for us to find the IP address of our Hill share module if we set it up to DHCP we'll also look at how we can find the IP address of the Animus module in another video but please follow us and subscribe to our channel so that you can take a look at all the informational videos that we provide thank you

---

# How to Find the IP Address of Your SCU6x Controller for Remote Access

URL: https://r2r.tech/videos/how-find-ip-address-your-scu6x-controller-remote-access.md

How to Find the IP Address of Your SCU6x Controller

In this tutorial, we'll guide you through the steps to find the IP address, subnet, and gateway of your SCU 6X controller using the tool icon, power user, and communication settings. Discover the type of module you have - in this case, an ethernet IP module - and ensure you're connected to the correct network to connect to the app.

00:00 Introduction to Finding the IP Address
00:14 Understanding the IP Address Details
00:23 Module Type and Network Connection

## Transcript

So, in order to find the IP address of the SC6X controller, we're going to go into the tools icon, bottom right, power user, and then communication. It's going to tell us what the IP address of the devices, the subnet, and the gateway. It's also showing us the type of module that we have. This is an Ethernet IP module.

So we need to know that IP address and be inside that network to connect to the app.

---

# How to Import SCU5 Controller as a Device into Rockwell Studio 5000 IO Tree

URL: https://r2r.tech/videos/how-import-scu5-controller-device-rockwell-studio-5000-io-tree.md

This video shows how to import SCU5 controller as a device into Rockwell Automation Studio 5000 IO tree.



For more information about the SCU5 controller please visit: [https://r2r.tech/products/roll-2-roll-controller](https://r2r.tech/products/roll-2-roll-controller)

## Transcript

hi this is Carlo from Roll to roll technology and in this video I'm gonna show you how to add su5 controller into a Rockwell Automation PLC first of all let me show you my setup I have my local automation PLC over here and I have my su5 controller over here and I have my sensor over here let's head to the studio 5000 and I'll show you how to add the device to object first of all we provide two different kind of interface through ethernet IP and we need to find out which one you are using to do this we can head to the su5 controller over here and go into settings power user communication and over here you will see the brand the kind of interface that we you are using in this case is the heel chair so let's go back into the studio 5000 we will go into the io tree and right click on the ethernet and add a new module and we're going to search and type r2r and have the wheelchair controller over here and do create over here you will give a name to the controller I'll call it demo and you will type in the IP address the you can if you don't know this you can also find that on the su5 controller over here you will see the either the IP address for the controller which is the IP address you need to put into the studio 5000. you will enter the IP address here one two three one couple and then Define your connection Click Change exclusive owner you will need to change this from s int to int and press ok vs and then if you want to change the RPI which is the interval at which the PLC talks to the su-5 controller you can do that over here we are going to leave it at 20 millisecond for this demo and that's it I'm gonna click ok you click ok and close and now you have your su5 controller over here and you will also see that under the controller tags you will have the generated automatically the variables they show you the input and output register over here now I'm gonna download the program and verify that I can actually see data coming in and out of these so I'm gonna go online I'm Gonna Do download yes I'm in run mode the controller is okay the i o is okay I can verify that the connection is running properly and I can look at the input data I have some data coming in and if I move my finger in front of the sensor I have data changing so I know I have a good connection to the device let's say if by mistake you other than any bus IC module instead of the proper e-share model let me show you what happened that's when you try to go online download you see now you have the i o no responding message over here and if you go to the any bus property you will say that status is IO faulted and you get uh never say that that key is mismatching that's an indication that you have an improper configuration of the SEO 5 controller another common mistake is to forget to change the sides of the variable from as in to end in that case what will happen is the variable that automatically created when you add the device will be of the wrong size so there will be eight bit variable or short end and in case you are using our aoi instruction this variable will not match the sides that the aoi extraction is expecting so the AI won't work also if you decide to do your own conversion of the register into the real variables this won't match our documentation so it will make your high life a little bit harder and there is one also thing to notice that if you once you realize the mistake if you go back and try to change this back to end and say okay yes and okay even though you change it Rockwell at that point won't change the size or the variable they were created so in that case to fix the problem you have to go back delete the module and add the module from the beginning in your module I have to R e a name demo IP address and this time make the right selection here okay close and now if we open the variable we see the int or 16 bits this matches the size that the aoi is expecting and the match is also the documentation of our website and this concludes the video on how to add the su5 controller into the aoi tree for a Rockwood project

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# How to Import SCU5 EDS file Into Rockwell Automation Studio 5000

URL: https://r2r.tech/videos/how-import-scu5-eds-file-rockwell-automation-studio-5000.md

This video shows how we to import Electronic Data Sheet (eds) file for the SCU5 controller into Rockwell Automation Studio 5000 software.



👉🏻 EtherNet/IP EDS File for SCU5 firmware Version 3.5+ using Hilscher Module: 🔗 [https://r2r.tech/documentation/ethernetip-eds-file-scu5-firmware-version-35-using-hilscher-module](https://r2r.tech/documentation/ethernetip-eds-file-scu5-firmware-version-35-using-hilscher-module)



👉🏻 EtherNet/IP EDS File for SCU5 firmware Version 3.5+ using HMS Module: 🔗 [https://r2r.tech/documentation/ethernetip-eds-file-scu5-firmware-version-35-using-hms-module](https://r2r.tech/documentation/ethernetip-eds-file-scu5-firmware-version-35-using-hms-module)



For more information about the SCU5 controller please visit: [https://r2r.tech/products/roll-2-roll-controller](https://r2r.tech/products/roll-2-roll-controller)

## Transcript

foreign Technologies and today I'm going to show you how to add an su-5 controller into a Rockwell Automation PLC this video today will be pretty much in three parts first I'm gonna show how to include the ESD file to the Rockwell Studio 5000 system first of all let me show you my setup over here I have a Rockwell Automation plc I have my SEO 5 controller over here that is connected to a sensor to download the ESD file we're gonna head to our website r2r.tech resources documentation support files and then look for the EDS file for we're gonna do wheelchair first this is the ethernet IP EDS file for SEO file right click save link as choose the folder where you want to have it save it and now we can head back to Studio 5000 and go tools ESD Hardware installation tool this is going to take a second next register on ESD file next browse to the folder where you have your USD file open next next next and next you have successfully completed that yes file okay to verify the installation went through properly we are going to try to add a a device into our io3 after installing a new HD file right click module and then I'm gonna search for r2r and device is there that means that the importing of the ESD file was done successfully I'm gonna skip this for a second sometimes we have had some customers that say that this procedure doesn't work another way to do the same thing is to go into the Rockwell yes Hardware installation tool there is a standalone application from Rockwell that provide the same functionality and in this case is at and you do follow the same steps you browse from the ESD file in my case is this open next next and you get to the same point you successfully completed the ESD grid and then you can exit the application so we provide two different kind of ethernet IP interface one is the wheelchair that we just installed the other one is the any bus so to import any bus ESD file the procedure is exactly the same I'm gonna head back to the artwork.tech slash documentation website and this time I'm gonna download look for the HMS module this is any bus I'm gonna do the same thing click save link as choose the folder when I want to save it and then I'm gonna head back to Studio 5000 again tools EDS Hardware installation tool next choose the file that I just downloaded this is the manipas I see next successfully completed the ESD wizard finish I'm gonna go back and verify that ESD file was properly installed new module this time I'm gonna search for any bus and any bus I see EP this is the device that we just installed so this installation was also successful and this is the first part and this covers all that I have for today thanks for watching and if you want to stay up to date with all of our videos please subscribe to our Channel down below and have a good day

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# How to install an upgrade kit for web guides

URL: https://r2r.tech/videos/how-install-upgrade-kit-web-guides.md

Do you have an existing web guide with outdated sensors and control unit? We now have a solution with our upgrade kits featuring Roll-2-Roll® Web Sensors and Control Units for all electromechanical web guide systems, providing advanced edge and center guiding capabilities.

## Transcript

Hi, this is Pedro Velasco with roll-to-roll technologies in a previous video we showed you or we talked to you about the advantages of using a retrofit kit when you need to replace your existing web guiding system especially if you're a integrator or a rebuilder of machinery even an end-user. This is one way to save some money, so you keep the mechanical part of your web guide But then you use a retrofit kit in order to improve its application now You're getting the best in controllers and the best in sensors technology available at that time so Whenever you order a kit from us you'll probably get a Control unit which is clearly labeled and helps you in the orientation as to how the screen will be. So you will have the sensor Ports and then you will have on the side power connection the motor connection And if you have order an Ethernet communications option it will be there, too. You will also get a sensor or sensors depending on what your application Maybe even a sensor rail if you need so But that it's up to the user as to where they want to place the sensor.

You also get an actuator With it's a own motor driver and then a servo-center sensor with its brackets right. And then all the other accessories are required in order to do the installation. Ok so the first thing you would like you would want to do when you receive your Your kit is you want to verify that it it's in working condition I mean we do packages the best way possible we want to avoid any problems. So the first thing you do is you power up your control unit and you will receive a Connecting cable like this, but for the sake of this demonstration.

We're just gonna use a pre connected power supply. So you will connected to your power power right and then the screen should light up right and then you can proceed to Connect your sensor now remember our technology allows you to do this without having to do any calibration so it's a very simple and a very simple operation so Here you go, so I have now connected my sensor And I can verify if it's working as you can see on the screen, it's working so that we have done that step so After checking your the control unit with the sensor and just powering it up we want to then proceed to Installing the motor so when you get the motor or the actuator you will get an actuator with the mounting bracket And the motor driver okay? So first of all we just want to do is we're gonna do a wiring here Show you how to how you can connect the wiring, but typically we will give it to you pre-wired now There are some exceptions people have some special requirements And they want to do a wiring themselves, but will also give you instructions how to do the wiring. But in this case we're just gonna go through the whole process so first of all you would have to install the bracket I'm gonna use this The plate that we have for the demonstration purposes, but you would have to have this already pre-drilled It's a 4m 4mm screws and then we just Do the just put the bracket on and screw the bracket on to the plate so one thing that you have to be Cognizant of as we're installing the bracket We also have to install the servo- center bracket.

Now the service center bracket now only has one position it goes to this side right so you have to install it at the same time you're installing the motor bracket and so you use your 4mm 4mm screws and you have to install it within the brackets into the plate So here I show you that I have installed the bracket and installed the other bracket for the motor or for the actuator and the bracket for the servo-center As you can see I have the screws mounted here in here right something you have to consider you have to align the motor make sure that this bracket aligns the motor with the the Connection for the actuator to the web guiding mechanism right and of course the servo- Center. It has a one position only so and that will get installed in the next step. Okay, so once I have all the brackets installed then and I have aligned it then I place the motor and notice that I am placing the motor with the cable side on Opposite of where the several Center bracket is at right. I would screw this on and then I would get the servo Center sensor So in order to install the servo-center when it comes it has two nuts right and so you Put it through the hole on the servo-center bracket install the Locking nut and just Score it back on and one thing that you have to do is we recommend that you have the distance between the face of the servo Center sensor and the screw of the actuator An eighth of an inch is a pretty good distance that will work enough and you can actually adjust that by just adjusting the back Nut in order to create the space Okay, so now that we have installed.

Let me give you a piece of advice because there are certain vibrations on the web guides that is operating and you don't want the servo-center to Sensor to move we recommend that once you have determined the appropriate appropriate distance of the servo-center sensor Just put a little drop of Loctite glue on the back nut and then after you secure the front nut then before you secure it just put a little bit on that too right and that will keep the sensor in position. okay, so now that you have installed the Motor on the motor bracket or the actuator on the motor bracket and the servo- Center on its bracket Then we want to do the wiring. However we provide the driver Motor driver in this enclosure. Now you have two options to put places enclosure within your operation one is a you actually fix it to a plate or something where you can just drill a couple of holes.

We provide the Dimensions for this for you so you can do that that operation. You would probably recommend a m3 and screw on this. However We also provide the option where you can just put it on a din rail, so those are two things you can do when installing. Okay, so When we're going to wire this, it's clearly labeled we will provide you with a sheet where it gives you the locations of each of the wires.

However typically we will send this to you pre wired But in the case that you need to do it on your on your own we have provided this sheet And you'll find that on the p1 section, which is clearly label p1 you will have all the connections for the motor in the Connection from the control unit to the more and on the p5 section. You will have the connections for the servo center unit So before we start connecting cables. Let me give you a word of advice You may not you should not connect the motor Or plug in the connection to the control unit that goes from the motors From the motor driver while the control unit is on This will it's not recommend it so Always every time you can do some operation where you need to disconnect the motor from the motor from the control unit Make sure that the control unit is off Alright, so for the sake of time we went ahead and wire to this. This took us about five minutes to do the wiring but as you can see we followed the table that we have here.

It's all pre-wired according to the table and as I mentioned before never plug the motor driver to the control unit while the control unit is on. So as you can see right now we have we have our control unit off. We're gonna go ahead and proceed and connect the motor driver to it. Now that I've That I've connected the motor driver to the control unit I can proceed to put power to it so Now one thing that we recommend once you do this is just make sure in check that everything is operating so with the control unit on the manual which is when it's lit red.

We can actually check the position of the motor. Just move it around right so We can jog it to one side or jog it to the other side Furthermore we can check the servo-center now. Here's something that we want to tell you about servo- centers sometimes Typically we will send you this already preset But in case it s move or something like that you might notice that the servo- center might be off. It might be because It's in the wrong position, so what you want to do is adjust it.

Now you can find adjust it by moving the servo- center in and out to things you don't want to do you don't want it to be crashing against the the stem of the of the actuator and Second thing is you don't want it to be too far away otherwise it will just go to either one of the Extremes right so once that is set we are ready to then test with the sensor now when we're connecting the sensor to the control unit you have to be very careful because the pins inside the connector are very very fine. So the connector will have a notch and you have to align the notch to the port. So the port rule house will have a notch in there so align those those two and Just don't push it in too hard. Just align them and just screw it right on.

It will come in completely and connect correctly and as you can see right now, so The sensor doesn't detect anything right but right now It's in manual mode, so nothing will happen But I'm gonna check and see and yeah the sensor is actually seeing this the finger in if I put it on automatic Okay it will start moving and then I can verify the sensoring. I servo-ceter again, and it's ready to go when you're specing the motor we actually provide you that the motor comes with an m6 thread On the on the end of the of the shaft motor shaft, however We usually will you know we can work with you if you have another need. Also we can provide you with Different size motors depending on your needs so if you have an application that requires more thrust we can give you a bigger motor or the standard motor that we put in some of our web guides, or if you have a very small application we can use a smaller motor. It's all depends on your needs So all you have to do is just tell us about what your needs are with the motor and you know the connection to this to your web guide it can be you know a Ball joint that you know there's many applications that you can do with this However anytime you need something like this.

We just spec with you we talk to you and we we help you inspecting the The connection for your web guide. So with all the options that we have in motors All the options we have in controls and on it you can apply this to any type of guide Any type of guiding application that you need for example you can use it on a steering guide or a displacement guide even for unwind and rewinds and Just by changing the motor we can use it in any of those applications We we hope this information is useful to you in how to use or how to install one of our retrofit Kits now one thing that we want to emphasize is this is the same technology that is on all our web guides so if you want to see other features that we provide within our control units with our sensors you can look at our some of our other videos that we have through our website. You can see other applications we can do with our sensors. You can see you know how we can actually give you some other features and Make your operation easier to run so We hope this will be a help to you and just contact us or look at our website www.r2r-tech.com

---

# How to install or replace Rollers on a web guides

URL: https://r2r.tech/videos/how-install-or-replace-rollers-web-guides.md

Having the right rollers on your web guide is an important part of making it run efficiently. Our web guides makes it easier than ever to use the rollers you need. Watch this video to learn more about removing and replace rollers on our web guiding system.

## Transcript

Hi, this is Pedro Velasco with Roll-2-Roll technologies. Today I want to teach talk to you about how to install a roller on our web guides. Now in some situations you might have that you purchase a web guide from us but you require a special coating on your roller. Well we don't carry those in stock but we can tell you where you can find those rollers from one of our suppliers.

And so the best thing we can do is teach you how you change the roller or how you install the roller on your web guide. So when we give you a web guide when we send it to you you will have the shafts for the roller already installed so they're gonna be located here and they're attached with two m8 screws on each side. So just remove the m8 screws and remove this shaft. So this is one of our typical and groove rollers that we have in this case the roller will have when you receive it it will be covered in a black protective fabric and then it will have two rubber bands on the edge so you just take the rubber bands off and leave a protector protective fabric on it until you're finished assembling it.

But for so you will have on, either side, one side of the roller you will have a little bearing which is actually going to help it's a pressure bearing so it keeps a pressure on the shaft as you're assembling it. And then on the other side you will have two set screws that will actually lock the position of the shaft on the bearing. Now these collars kind of move around so they are pivoting collars. Okay so the first step to do is install the shaft into the the roller into the roller itself.

So you go through the collar that has the little bearing ball bearing on it and just carefully install it in there and just push it through right. Now it should go all the way through to the other side to the other collar and then you will have to look on it on this side just to align it. So once you have it aligned just push it through all the way up there okay so it goes out. Now one of the things you'll notice is we have to kind of center this shaft on the roller.

One of the best ways we found out is this measuring the distance between the end of the shaft to the on the on the roller. You could use the vernier for that. So we'll just take some measurements here. This one has a hundred point one six zero inches on one side and on the other side it should be very close to that.

It has point one eight one. I'm gonna measure that again point one eighty five. So what I do, this is pretty close to center, so what I do I just give it a little tap on one side and see how much it moved. Point one six six point one seven seven- that's close enough.

Okay so I have a ten thousandth of an inch difference between either side so that. So now we proceed to lock the shaft in place now the roller face will have a little cutout in it which is gives us access to these set screws. So you align the set screw to the to the cutout and just tighten it. Now for this you will need a 1/8 inch allen wrench.

so once you have it set and tightened then you can proceed to install the roller onto the roller plate. And this is a fairly simple operation just align the holes of the shaft to the holes on the rollerplate. Place your m8 screws on it just throw them on and just finish it off by tightening with a 5 millimeter allen wrench. And just give it a once you come to the lock just give it a quarter turn that'll be enough.

And you have assembled or placed a new roller on your web guide then you can remove this fabric and you're ready to go. So we hope that this helps you in doing a change of our roller assembly onto the roller plate and just watch on our YouTube channel for more instructional videos. You can also go to www.r2r-tech.com and see other information from our products.

---

# How to make fine guide point adjustments on our web guides

URL: https://r2r.tech/videos/how-make-fine-guide-point-adjustments-our-web-guides.md

Check out our newest feature in web guide controls for our web guides, which allows you to change the guide point without moving the sensor!

## Transcript

Hi this is Pedro Velasco with Roll-2-Roll Technologies. We're going to talk a little bit about adjusting the guide point on our sensors for the web guides In many cases people want to be able to do this adjustment without having to move the sensor, and that's what we're offering now with this feature that we're going to talk about. Today, we have what we actually have two ways of doing this guide point adjustment. Ones a gross adjustment the other is fine adjustment.

We're going to talk about the fine adjustment Which is something that some of our customers have requested us to do. In this case we can provide you a fine adjustment of a little bit over .25 millimeters per step that you're going to adjust. Now this adjustment has to be done while the web guide is on and the machine or the converted process is running at the same time. We got set up on our test machine with one of our web guides with this condition.

As you can see I'm going to put the web guide on automatic and let's start our machine. So right now on our Display you can see that the two sensors are on. We actually Installed 221mm sensors on our machine in order to do a center guide. And let's say at this point.

It's the Web Material is centered on the web guide. If I want to move it to the right four to five millimeters all I have to do is press this button. and they'll recorded this there and this set. You don't have to do anything else.

It's already set that the guide point has been displaced .25 millimeters to the right and I can keep on displacing the guide for as long as I think the material is within the sensing window. Now if I want to place it back to its original position all I have to do is hit the center button. And it's in fact there. As you can see I don't have to do anything else.

All I have to do is press those buttons and it gets back there. If I went to move the guide point to the left, I hit the other Direction. As you can see it implements a little bit over 0.25 and it's excellent now. What is that value?

Well in this case is you can be very precise moving the web as you process the material. In another condition that we have, you can do gross adjustments, but we'll talk about that in a future video. now this is only available in our latest firmware version for our web guides, version 2.4 right now [this] is available for you, and actually give you more control of the web material as you're processing it. So thank you very much and let's hope to see you again in our next video

---

# How to make gross guide point adjustments

URL: https://r2r.tech/videos/how-make-gross-guide-point-adjustments.md

Check out our newest feature in web guide controls for our web guides, which allows you to change the guide point without touching the sensor!

## Transcript

Today we want to show a feature in our web guides that allows for guide point adjustment We can do a fine guide point adjustment or a gross guide point adjustment without having to physically move the sensor The adjustment can be made on the operator interface by just sliding our finger across the screen In a previous video we talked about the fine guide point adjustment and today we want to go over the gross point adjustment For that we have to go to the operator interface screen, and there is a black bar on the screen and all you have to do is slide your finger across the black bar and it will move the guide point After that you will need to hit accept and the guide point will be set Unless you hit the accept button after moving the guide point, the system will not register the change in guide point If by mistake you touch the screen and move the guide point, the guide point will return to its original setting unless you hit the accept icon This is just another of our features on our web guides available in the control unit version 2.4 which is standard in all our web guides since June 2017 Fine and gross guide point adjustment, something we believe will be very beneficial for any converting operation Visit our website at www.r2r-tech.com for more information on all these features

---

# How to Reset Guide Point for Center Guiding on the SCU6x Controller

URL: https://r2r.tech/videos/how-reset-guide-point-center-guiding-scu6x-controller.md

## Resetting the Guide Point in Center Guiding with SCU6x Controller

 This video explains how to reset the Guide Point in Center Guiding using the SCU6x Controller. It demonstrates the process of center guiding with two sensors and showcases how to reset the guide point and adjust the offset. You'll learn how to manage the actuator direction changes and understand the reasons for allowing a guide point offset even when aiming for center alignment. This feature is particularly useful if the sensor was not installed correctly, providing a convenient alternative to physically repositioning the sensor.

 00:00 Introduction to Center Guiding

 00:12 Demonstrating the Reset Guide Point

00:37 Guidepoint Offset in Center Guiding

00:52 Purpose of Guidepoint Offset

## Transcript

One of the other things that I want to show with center guiding is that you can do the reset guide point just like what we did with edge or center guiding with two sensors. Let me show you that. Going back to the screen here, we have the web now and the green position indicates the center line position. If the web is moved that way and for whatever reason you need to do that, you could do the same reset guide point and accept.

Now the guide point offset is there. If the edge position goes on either side, the actuator changes its direction back and forth. This is for doing the center guiding with the point offset. Now, like I said, it's not usable for you to change the guide point offset with center guiding just because you want the material to be aligned to the middle of the machine.

The reason why we allow you to do that is that let's say you had not installed the sensor at the right location to begin with. Instead of going and physically moving the sensor, you could just move the offset. And that's the reason why we allow a guidepoint offset even when we do center guide.

---

# How to Set Static IP Address on SCU5 Controller with Hilscher Module

URL: https://r2r.tech/videos/how-set-static-ip-address-scu5-controller-hilscher-module.md

How to Set Static IP Address on SCU5 Controller with Hilscher Module

## Transcript

now that we have seen how the DHCP Works let's go back to our controller and look at how we can set the static IP address so if we go back to the controller and hit the tools icon and power user communication now we want to set the static IP address of the device what we are going to do is we're going to turn off the DHCP and then press set again it's going to do the power cycle because whenever we turn off the the hcp it needs to power cycle to get that setting and if we go back into tools power user communication it's going to show an IP address and this IP address is the last IP address that we set on the controller and this is again a static AP address and if we want to change the AP address what we're going to do is click on the IP menu there and type in whatever the IP address is 192. 168 0 0 1 and if we want to set it to and then we're going to press set and then that sets the IP address you might have to click it a couple of times to refresh and and now the actual IP address of the device is 192 168 1.100 again just to make sure this IP address is set properly you can switch to your computer and then type in the address on the web browser and when I type in the IP address on the web browser it shows up 192.168.1.101 is the IP address and that device is connecting and it's you can see the data coming through the controller so that's the way in which we can set the static AP address one thing to note is that anytime we change the state from static to Dynamic with our Hill share module we're going to have a power cycle and that's normal that's that's intended for us to have that power cycle this will not happen with a HMS module with an HMS module the device will not power cycle when you switch from static to Dynamic and you will have to manually do that and in a subsequent video we'll look at that as well thank you for watching and please subscribe to our channel for more videos about how to use our device how to configure our device and applications

---

# How to Set the Actuator Parameters in SCU5 Controller

URL: https://r2r.tech/videos/how-set-actuator-parameters-scu5-controller.md

This video shows how to set the actuator parameters on the SCU5 controller. 

Since Roll-2-Roll Technologies offers several different actuators from different vendors, this allows for lot of flexibility for the end customer. 

👉🏻 More information on the actuator are here: 🔗https://r2r.tech/products/roll-2-roll-actuators For more information about the SCU5 controller please visit: https://r2r.tech/products/roll-2-roll-controller.

## Transcript

hello everyone this is arvind seshadri from Roll to roll Technologies today we're going to touch briefly about our actuator settings how do we set different parameters on the actuator on our scu5 all of our su5 controllers have the ability to connect to a variety of different actuators that are driven by stepper Motors we provide our own drivers for it if you look at our documentation you can see that from the su-5 controller we go to a motor driver through the motor communication cable and from the motor driver we go to the actuator through the actuator cable because we have the flexibility to connect a multiple different types of actuators we also provide the ability to set up some of the parameters of the actuator through our su5 controller that's what we're going to look at today and we're going to see how to set the stroke of the actuator the pitch of the actuator the speed the polarity and so on and so forth we do have our one of our actuator connected right now to the scu5 controller and that's the one right here and this is this is our standard upgrade kit actuator and this one has a front spherical eye and a rear spherical eye and then it has bearing supporting the the actuator to extend and retract and this is our LHS series with a four inch stroke this actuator also has a Servo Center sensor that is installed right here and that's actually looking at the rail that is going in and out the servo Center basically allows us to quickly Center the actuator or home the actuator to a position which makes the web guide be parallel to the other rollers within the machine we'll also go through that in another video but essentially we have our actuator connected here and then if you use our sc5 controller to move the actuator you can see that the actuator is moving back and forth and that's also seen on this bar graph right there so we'll take a look at how we're going to set some of the parameters that can be done by going into the tools icon and then power user and then actuator and this provides you with some of the settings that are currently available and this shows a pitch of 0.25 inch a stroke of 1.38 inch there's also a motor polarity setting here and then the speed and the acceleration but when we ship our controller we based on the actuator that is purchased we preset those values in the controller and ship it but if you want to change it it's pretty simple so for example if I want to change the speed I can just drag this right there and set the speed and we can also change the acceleration the speed and the acceleration can be changed independently and the pitch of the actuator is depending upon what the actuator is and that is basically one revolution of the motor how much is the actuator going to extend or attract in our case this particular actuator has a pitch of 0.25 inches and that's what it is set up there if you need to change the pitch you can just press this button and it's going to increment or decrement the pitch the units right now is shown is in inches and if you want to see those units in millimeters you can go to this screen hit the operator icon hit the display and change the units to millimeters and once you do that you can go back to the power user actuator and you can see that the actuator units are now in millimeters this is about 6.5 or 0.25 inch approximately and then the stroke is 35 millimeters and you can probably set it to the stroke on the actuator the stroke that you set is not the actual mechanical stroke that is available on the actuator this is just an electronic limit in order to avoid some of the pitfalls with existing some of the other actuators that are available where if there's issue let's say the web breaks the actuator may go back go to one side and it might keep driving because it has Reach This limit it doesn't know it has reached this limit and it keeps driving it and that might burn out the actuator to prevent that from happening in our case we actually have an electronic limit that means that if the actuator reaches its electronic limit whether the actuator whether there is a mechanical limit or not it will stop just to show you how that works I'm going to set the stroke to be some really small number let's say 30 millimeters and if I go back to the home screen and I try to jog the actuator you can see that it's going in and right now the actuator position is it's showing that it has reached it's fully retracted limit even though if you look at this actuator there's a lot of stroke remaining so if you look at here there's still a lot of room for the actuator to retract more but it stopped at this electronic limit just to prevent it from burning or destroying the motor so the electronic limit can be any limit that you set and that limit of whatever that the stroke that I showed again if I go back to the screen and to the actuator you can see that the 30 what that 30 means is that it's going to be 15 from the middle of the actuator position and on one side and then 15 on the other side and that's what the stroke means so if you are in the middle position of the actuator you can go 15 on one side and 15 on the other side that's what the stroke means in terms of setting there's also the polarity so what we can do is we can change the polarity and if you remember when I did this when I pressed the Plus it was going in a certain direction and if I do this when I press the plus it's actually extending in the previous case when I pressed the plus it was actually retracting and that's also shown here in this position when the polarity is the standard polarity the plus will increase the actuator position and that's what this is showing and the negative will decrease the actuator position so it's retracting if we reverse the polarity then it will do the opposite and again when we reverse the polarity that it clearly shows here now if we press the plus it's extending retracting and then if you do the minus it's actually extending so the polarity can be changed as I'm moving the jogging the actuator back and forth one of the things that you can notice is that the this bar graph changes color and right now it's in yellow or Amber and then if I go to another limit and now it becomes red this is more evident in the other direction so if I go all the way in the other direction this is going to be yellow and then if I go reach a certain it goes to Red this is a quick visual indication for the operator to know that the actuator is close to its extreme position if not at the extreme position if it's in red it's within 10 percent of the extreme position limit and if it is in yellow then it's between 20 percent to 30 percent of the extreme limit so we don't typically like to run the web guide in this position is that there's not enough room for correction in this direction so if there is an error in this direction and the actuator needs to move that way there's not enough room to correct for it so anyway a quick visual indication for us to see where the actuator is again if you want to see that in a bigger screen if you just click on that motor icon then you can see that the same bar graph that you saw on the home screen that's essentially the things with regard to the stroke and the pitch and the the speed and the polarity again just to reiterate there is a difference between the mechanical limits and the electronic limits the mechanical limits are the actuator cannot move anymore because it's mechanically inhibited and we never want to set that actuator or install the actuator in that scenario where the mechanical limits are reached the electronic limits are just safely limits and this allows us to stop the actuator from moving even before it reaches the mechanical limits so we typically suggest that you install the actuator move it back and forth find the Home position set the home position or this Servo Center position and then set a certain stroke and then jog all the way to one side make sure that it doesn't hit the electronical limits and jog all the way to the other side and make sure that it doesn't hit the mechanical limits and as long as it doesn't then the electronic limits are fine if in any scenario whether you're going jogging left or jogging right it hits the mechanical limits then you would have to reduce the electronic limits so we never get into that situation where the actuator might hit the mechanic that's all we need to do in terms of setting up the actuator in terms of the stroke and the pitch there are other few functionalities that are available for certain controllers for example the actuator position if it reaches the extreme position there is a way for us to set digital outputs so that not just an operator needs to look at it but the digital output can provide a signal to the PLC to alert PLC that hey the actuator has reached this limit the other option that we have this is mainly for our big actuators that are moving the unwinds and rewinds which are susceptible to damage if we reach the mechanical limit that we can add additional limit switches either mechanical limit switches or even electronic limit switches make sure that the mechanical limits are never reached and if we have that option if we have the hardware provided with your actuator then you have the ability to enable them the way to do that is to get into the tools and then the power user and then in the controller there's this limit switches icon button and then we just need to turn on the limit switches if you don't have the limit switches and you turn on the limit switches the actuator might not move just be aware of that but if you do have the limit switches and you want to enable that functionality then you can enable that functionality by turning on the limit switch so those are the basics of the actuator settings in terms of stroke pitch polarity limits and limit switches in a subsequent video we'll talk about the servo Center functionalities but in the meantime do subscribe to our Channel and we'll see you in the next video

---

# How to Set the Password Protection on the SCU6x Controller Screen

URL: https://r2r.tech/videos/how-set-password-protection-scu6x-controller-screen.md

This video looks at protecting access to the operator and power user screens through the use of password protection in the SCU6x Controller. It shows how to enable and disable the password, explains the different user levels, and how to change the passwords. The video also covers important information about default passwords and the process to reset them if forgotten. Operator Screen Access Protection.

## Transcript

We talked about this tools icon here and one of the common questions that we get asked is is it possible for us to lock the screen so that only people who have privileges to access that have access to it and we can do that in our password screen right here. This password screen allows the operator or the power user to lock certain parts of the controller so that the access is restricted to those who are familiar and knowledgeable about what the consequences of the changes would be. So there are two main user levels. This one on the top is what we call as an operator level axis.

This would be any operator that needs to change certain things with respect to the controller including setting up the sensor. If you want to do line guiding, contrast guiding or pattern guiding, all of those are available to the operator through the operator screen. If I click on that, you can see the things available for the operators to change. Again, setting up the sensor.

If you're doing width measurement, you can look at the different width measurement options that we have. We'll go into detail about this in a later video. And then the next level of access we have is the power user. This is somebody like a maintenance professional or anybody involved in commissioning our system.

Most of the functionalities here are one-time kind of things that you need to do when you try to install the system for the first time. So again a setting related to the actuator some other high-level sensor related settings controller options and communication if the customer wants us to enable or disable certain access levels we can do that and that's available in the power user to be able to do it. One of the questions that we get asked all the time is how do you know when a password is enabled or not? As long as you see these icons, that means that the passwords are not enabled.

If I go in and enable the password on the operator screen, then that icon has disappeared. So, you won't be able to have access to that unless you enter the operator password. Likewise, if I go in and lock the power user screen, we won't be able to see the the icon for that. Nobody would be able to enter it unless you enter the password.

That's essentially how you would enable and disable the password. [Music] If you want to change the password, there's an option to change the password. All you need to do is pick the password you want to change. Let's say the operator or the power user.

You would click that, enter your current password, and then change it to new password. So, the passwords are fourdigit long. and please contact the factory to get the default password information. Once you have the default password, you can go in and change the password for the operator screen and the power user screen.

But please note that once you change the password, there's no way that we would know what the password is. So, we wouldn't be able to recover that unless you send the controller back to us. So, that's essentially what this password screen is. [Music]

---

# How to Set the SCU6X Controller for Multiple Web Width Measurement

URL: https://r2r.tech/videos/how-set-scu6x-controller-multiple-web-width-measurement.md

Multiple width measurement is an application that many operations in converting would like to have. Much better if the application was capable of simultaneously measuring and monitoring the widths of several webs. Join Aravind Seshadri from Roll-2-Roll Technologies as he delves into the capabilities of the SCU6X controller and ODC sensors for web width measurement. Learn about the unique advantages of one-sided sensor technology, such as ease of installation in tight spaces and high resolution, independent of field of view. Aravind takes you through setting up single and multiple web width measurements, including the ability to measure widths of up to 32 strips simultaneously. Adjust settings for nominal, upper, and lower limits, and understand the importance of calibration for high accuracy. Discover how automated data collection and Ethernet connectivity can streamline your web handling processes.

 00:00 Introduction to Web Width Measurement

00:36 Advantages of ODC Sensor Technology

03:00 Setting Up the SCU Six X Controller

04:22 Operator Width Screen Overview

06:59 Configuring Limits and Alarms

11:06 Calibration Procedure

16:18 Pattern Teaching Mode

19:27 High-Resolution Measurement and Compensation

23:00 Digital Output and Stack Light Integration

25:00 Conclusion and Next Steps

## Transcript

Hello everyone. This is Arvin Shadri from Rollto-roll Technologies. Today we're going to talk about web width measurement with our SCU6X controller. One of the key things with our SCU6X controller and the ODC sensors is that they not only are used for guiding purposes, they're also used for any type of cross machine direction width measurement applications.

It could be measuring the width of a single web or multiple webs. Here again to reiterate on some of the advantages of the ODC sensor is that it's a one-sided sensor technology. So it allows us to install the sensor in tight installation spaces whereas a camerabased traditional machine vision system might need a long longer field of view and working distance which creates issues if you want to add an width measurement system to an existing machine. The other advantage is that the light source, the optics and the camera, everything is built into a single interface like what we have here.

We don't have to have a separate light source or gantry to have the camera and the light source built in. The third advantage is that the sensor provides a one:one magnification. If the object is 100 mm wide, we're using a sensor that is at least 100 mm wide. So, we get a 1 one magnification.

The advantage is that when you go to a wider width, you don't lose any resolution. So for example, this ODC 960 which is a measuring range of 960 mm can provide the resolution of 127 micron on the camera level and then sub pixel with that you could get up to about 33 micron resolution. your resolution is not affected by the field of view that you are requiring. Because of these advantages, the ODC sensor is used for a lot of different applications, especially in existing sliver rewinders where you want to measure the width of the material.

Today, we're going to talk about something that is unique to our solution to measure multiple widths with the same system. The advantage of this is that because it's one-sided, we can have multiple webs ranging from one web all the way up to 32 webs per sensor. So that's what we're going to discuss a little bit. We're going to talk more about how this can be set up in the controller interface and then we'll also look at in another video how you can get the data out and what you can do with the system.

Okay, I've got this controller set up right now the home screen on this. The first and foremost thing that we're going to do with the SEO 6X is basically kind of pick the application. SEO6X is a pretty versatile controller. It can be used for a lot of different applications.

So in this case, I'm going to set it up for width measurement application. Could be a single web width or multiple web width. And once we do that, we can go into the sensor screen. Right now, I have just one sensor connected here, but we can connect multiple sensors.

In another video, we'll talk about how we can have multiple sensors either with a gap between them or an overlap between them so that we can stitch the image of two sensors into a single continuous image. In this video, we're just going to look at how to do this with a single sensor. So, I have this connected to sensor one and then you can see all the samples there. Any setting in this is going to be very similar to what we have done in the past with the SC6X controller in terms of setting the brightness, the contrast and all those things.

We would ask you to refer to the previous videos to learn more about that. In this case, we have a pretty good image already done. So, we'll just go into that operator width screen to take a look at the functionalities and what we can do there. To get to the operator width screen, from the home screen, we're going to press the tools icon, then the operator icon on the top right, and then the width icon.

This first page is the operator width home screen. The second page is an additional setup screen where you're able to do more setup related things. We'll cover both these screens in this video. So in the first screen you can see that it is providing you with a lot of different things.

First it's showing you the width of the web and then the web number. And if you want to go look at the width of the next web, press that icon. It'll go to web two and it's going to show you the width of the web there. And you can keep scrolling through basically how many webs you have.

You can go through these two icons on the top allow you to scroll through the webs. In this case, we are looking at multiple webs. For each web, we can set an upper limit, a lower limit, and a nominal width. The units are in millimeters.

If we change the units to inches, then everything will show up in inches. So, just to show you how this will work in inches. You can go back couple of one screen and then go to the display icon in the operator menu. And then the units, you can change it to inches.

And now the units on this screen will all be on inches. Then like I mentioned for each web, we can set an nominal width, upper limit, and lower limit. Right now I'm going to show you how we can set those things. So in order to set the nominal width, we're going to press that nominal width icon.

And then we're going to choose how much increment we want to make. So I'm going to do 10 mm increments here. So I'm going to change that to 50 mm. Okay.

So the nominal width is 49.24. That's it. There's no need to save anything here. Anytime you change that, that parameter is automatically saved and saved into the memory.

So when you power cycle it, it comes back in. Likewise, you can set the upper limit and the lower limit. So you choose the parameter that you want to change and pick the increment. If I do 1 mm increment that's going to be like that and you can do it like that.

It's very simple intuitive way to change it. And likewise you can change those things too. Now there are applications where we would have two types of outputs. One is to say that if my width is above a certain upper limit or if the width is below a certain lower limit you want to trigger an output there.

So in those cases we would have something what we call as that upper limit lower limit kind of thing. So this is a pretty simple setting. All that we are looking for is hey if the width goes above my upper limit trigger an output or if the width goes below the lower limit trigger another output. So just two boundaries and then within the nominal range the output is not triggered all good signals are provided.

If you want an additional layer where you want to set alarm limits and warning limits then we can do that too. So in this particular case then you need to make sure that it is in alarm and warning. When you have this in alarm and warning you have this button show up. Just to show you one one more time.

If I have it just on upper and lower limit these are the two parameters we can enter. But if we are in warning and alarm there are four parameters you can enter. The first two parameters are here and the second two parameters are warning limits. warning signal so that you don't have to stop the machine when the warning signal is there.

This is just for the operators to know something is getting to get bad and once it hits the alarm limits then you can stop the machine if you wanted to. Just like I mentioned the warning limits are going to be closer to your nominal width and the alarms are typically farther away from there. So in this case we have it set as plus or minus.5 mm and then this is plus or minus.1 mm for that and you can do that for every single web. You can set the upper limit, lower limit, alarm and warning limits.

Right now for web two it's not set up. Web three you can see what is set up there. None of these are set up there. But that's the way for us to set this up for the alarm and warning so that when the width changes you have the ability to provide a digital output to a stack light or something like that.

So that is essentially how to set the multiple width measurement these warnings and alarms. And again just to go through this one more time I'm going to pick width two. I'm going to set that nominal width to be 49 point let's say.5 there. So I am in warning and alarm.

So I'm setting the alarm limits for this. So I'm going to set this as 1 mm and the lower one as 1 mm as well. And alarm I'm going to set this as.5 and 0 five for that. And then you can keep doing that for multiple webs.

And if you go back here, you can see for the different values, different webs, you see different values there. When I go from one to another, you got all of these set there. All of these are saved in the memory. Then you have that option to do it.

This is where you use the controller. An operator is manually setting this. All of this can be automated through Ethernet and you can send a recipe to our controller to say web one should be this width. The upper limit is this and the lower limit is this.

Upper warning limit is this and lower warning limit is this and so on and so forth. So just to reiterate this is the procedure for somebody to set up a job. If you want to have all of these alarm warning limits you can set for individual webs and then set them up. to make it simple.

If you have a recipe or a job number, you can automate this by setting these through Ethernet if you wanted to. One other thing we need to do whenever we are initially setting up is u one-time calibration procedure that can be done on this screen. The idea for this is that we have the ability to calibrate our sensor for your conditions. We do have a calibration done in the factory, but when it's being installed, the sensor might be installed at a different distance than what we typically expect.

And then there are other things with the lighting and contrast that might change some of these parameters. So this calibration is necessary only if you're looking for a higher resolution measurement. For example, if you're looking for a tolerance of plus orus 1/16th of an inch, you don't need to do any of these calibration things. But any anytime you are below that.

So anytime you're below a millimeter or below a 1/16th of an inch resolution, you would need to do a calibration. This is done just for that particular setup. Once you do it, you don't have to do it for the rest of the run. It'll be stored and take that calibration value.

What does the calibration do? Essentially, I have a material or a sample of a known width and the sensor is providing a raw measurement. We're going to compare those two and then say the calibrated measurement is based on the actual sample width and whatever the raw offset is, that's the correction we're going to use for the rest of the measurements. So, that's indicated here.

So that's basically saying what is the correction from the actual width to the measured width. That's essentially what the calibration is. So it's just creating a offset. So for example, let's say the sample width is 46.

To change that, you press whatever you need to increment by and change that value. I am going to put that as 49.244. Right now it's measuring 49.293. If I want to teach this, my sample width should match my measured width.

To do that, press this teach icon and then press accept. Now it has applied a correction. Essentially the raw width plus this correction gives me my actual width. And that's pretty simple.

It's just a regular bias or correction that we are adding. Nothing fancy about this calibration. So you can do that for all these other materials. We don't necessarily need to do this if your tolerance is 1/16th of an inch or 1.5 mm.

We don't need to do that. But for some customers looking for a higher resolution, you do that calibration procedure. Now, just to make it simple, you can enter all of these sample widths already and then you can do a one-time teaching. Let me show you how that works.

I'm going to enter this sample width here. Okay. So, if I want to do all of them together, I'm going to press this teach all button. Make sure that it's highlighted.

And then I'm going to press this teach and accept. Now, all these samples will have a correction. Before we had everything as zero. And if I now scroll through web 5, web 4, web 3, web 2, and web 1, all of them now have a correction.

So it's just a quick way for you to do this. The general use case for this is that let's say you are a customer in automotive or medical and you have a QC process where you are only sampling a part of your product. You're setting up your slitter. You pull the initial sample after the operator has set up the slitter and you take that sample and you're doing a QC on that.

Now essentially what you're going to do is take that sample and enter it like what I have here. Then you're going to do a teach all. Once that is done during any part of the run, we are taking that measurement online in line 100% of the time. So that's the biggest advantage with this system.

In your typical process right now, you might be doing one sample at the beginning of the run. At the end of the run, the operator needs to stop the machine, take that sample, give it to QC, take the measurement, and then everything is good. You run it, and then every time the machine is stopped, there is another sample that is taken. So, this is a random sampling process with a lot of time involved between one run to another.

and we completely eliminate that and allow you to keep running the machine and monitor the width all the time. So that's the biggest value proposition with our system and that's essentially it. So that will allow you to calibrate each of these samples and be done with it. Now we do have another feature that allows you to get even higher insight into your process and what that is what we call pattern teaching.

So essentially what we will do with the pattern teaching is that we set the widths, we set the samples, we set the job, we're looking for not only the change in the width but also change in the movement of the material. You can enable that by pressing this button. That's in the pattern teaching mode. When you're ready to teach the pattern, we're going to press this teach pattern and press accept.

So now the system is taught the pattern. What is the advantage of that? If I have uh let's say I'm in web 3, right? And if the web 3 breaks right now, it is actually showing you that, hey, I'm supposed to see a web there.

It's broken. The value is zero and it's going to provide an alarm or alert right there. That's one advantage of that. Another advantage with that is that let's say I have a web five that I'm tracking right here.

And if I have another material that comes in between there, the web f measurement is not affected by that whatsoever. In a typical camerabased system, they're going to keep track of the width randomly based on which one is first and which one is second. That would affect the measurement. If I do have this pattern off, web 5 will actually jump.

You saw that it jumped to that 10 mm and it jumps back to avoid this jump. We are going to use the pattern and once the job is set up in your slitter rewinder, it's not going to change. The pattern is not going to change. Then even if something comes in that gets completely disregarded.

That's the advantage with the pattern teaching or pattern matching mode. Those are the key things with regard to how you can set up our SCS 6X controller for multiple slit width measurement. Okay, one other thing that we wanted to show is that this width measurement right now we're in pattern mode. So even in pattern mode, if the web moves back and forth, you can see that the web is moving, but it's also keeping track of that edge position, keeping track of that width pretty accurately.

And we can actually move this quite a ways off and that's when it will say that the pattern is supposed to be there, but it has moved from its intended position. So this is an example where let's say the slitter blade moves too much then you can catch that. Obviously it'll show up in the width but it'll also show up in the web position. As soon as we come back into that location the actual location itself then it locks in on that.

For customers that are looking for really high resolution measurement and high accuracy measurement. We also have other features to compensate for the installation of the sensor. In the previous section, I talked about the brightness, the contrast and all those kind of things. But on top of that, if you want to get a really high resolution measurement, then there are a few other things that we can compensate for.

One of the compensation is for how the sensor is aligned with respect to the machine. Obviously, we want the sensor face to be parallel to the surface of the web and we want the sensor to be at a certain distance from the web. But it can be installed at an angle and even small angles make a big difference in the measurement. So the example would be if I have a sample that is straight but if I put it at an angle then I'm looking at the essentially it's basically a cosine kind of thing.

So you are adding more to the width than that. So there is an issue with how the web is presenting. Ideally the camera it's it's just a line but you have two sensors in there. So there are two rows.

So we want the web to be perpendicular to the two rows that we have. Now it's impossible for somebody to install it exactly perpendicular. So we have that compensation available there. So I will show you how we can take care of that.

So when you first install the system and you want to compensate for the angle, the way to do that is that we can go into the power user screen and from there you would be able to set this up. So to get there, click on the tools icon bottom right power user and then go into the sensor. You can see that sensor one and it's identifying as ODC960. This is the number of pixels it has and all those kind of things.

There are actually 10 cameras in there. So for these high resolution measurement when you when we set this controller up on the back of that sensor, we will have a factory calibrated string of 10 numbers that you need to enter. So it will vary between five and 15. For each one of them, it'll be a number.

You can pick that number and whatever that number says you can set that number there by moving the upper and lower numbers. That's the first thing we need to do. The second thing we need to do is compensate for the angle. So that that is another thing that we have in documentation that you can look at and it will tell you what that number means.

There is a small measurement that you need to make when you do the first installation. And once you have that, that number you're going to come in and enter in that last column. These two things are necessary if you're looking for a measurement resolution of sub mm, actually sub 250 micro. Anytime you want that high of a resolution, we need to make sure we have these things set up.

This is a factory calibration number that you need to enter. The slope correction is another number you need to enter in this screen. When we do multiple click width measurement and we have a digital output that triggers an alarm limit or a warning limit, you can tie that to a stack light. If you have multiple web widths, multiple split widths, then if any one of them is out of the range, then those stack light would get triggered.

So we have one output for alarm, one for warning, and one for all good. And if any one of those lanes violate that condition, you will have that digital output get triggered. Just to show you how that works. Um, I don't have a stack light connected, but I do have a signal that would go out when that happens.

And you can see that information on the SCU6X controller. So that's what I'm going to show. In order to get to that screen, press the tools icon on the bottom right and then the arrow key on the bottom right and then digital IO. We want to make sure that the digital output is set for width.

And then you can see a real-time view of what the three outputs are. Right now I've got output three enabled because everything is as per the tolerances. So if I move or change the width of this material, you can see that it it triggers that alarm when that width changes. So if I have something that is narrower, you got that those are the alarm limits and walling warning limits that gets triggered.

So like I said it could be any any lane and that will provide the visual output for the operator to know there is a warning or an alarm doesn't tell you what lane it is. When we get this data through Ethernet then you would have information about exactly which lane has the problem and what kind of an alarm that we have in there. So we'll look at that in the next video. Just to summarize, in this video, we looked at how to set up a single sensor for multiple slit width measurement where you can set it up just directly on the SCU6X controller.

And we also saw how when you connect to a digital stack light, when the width of any of these lanes go above or below the limit, then you have the ability to trigger that stack light. In the next video, we'll look at how we can collect this data through the Ethernet and what are the functionalities that we have through Ethernet. And we'll also look at the app that we have and the app, the data that we can collect from the app and so on and so forth. So, please follow and subscribe to our channel and we'll see you in the next video.

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# How to Set Up Web Width Measurement through a PLC

URL: https://r2r.tech/videos/how-set-web-width-measurement-through-plc.md

A programmable logic controller (PLC) or programmable controller is an industrial digital computer which has been ruggedized and adapted for the control of manufacturing processes, such as assembly lines, or robotic devices, or any activity that requires high reliability control and ease of programming and process fault diagnosis.



In this case, Roll-2-Roll Technologies programs the PLC for web width measurement in converting operations.

## Transcript

okay this is a short video about how to set up the width measurement sensor now the first and foremost thing is the sensor has to be connected to the power supply and to the Ethernet and then a cable goes into the PLC and power for the PLC and for the Ethernet as soon as we tried a new web we present the web take a look at the documentation on our website to say how far the web needs to be with the sensor but once you have that ready we can go into this settings screen and then go to wit setup this is where we would go in and set up what is the nominal width so whenever you start a new job you can probably measure the width of that in this case I've already done that it's 153 millimeters so I'm gonna go in and set hundred and fifty three millimeters that's my limit and then we're gonna press record wait it's going to save that as the correct width we can also set alarms and warnings so depending upon your application so in this case we'll go ahead and set an upper limit of one millimeter for an alarm lower limit of one millimeter for the alarm and then about 0.5 millimeters on either side for the warning these ranges are the ones that are going to trigger the stacked lights so whenever the web width is within the nominal width which is 153 millimeters in this case then you'll have the green light enabled and then when it goes about by about 0.5 millimeters you're gonna have the amber light enabled and then any time it goes about one millimeter you'll have the red light enabled so go to the home screen and you can see that since it is within the spec the greenlight is enabled anytime I go and it increases quite a bit then the red light gets enabled and if I just tilt it a little bit and the weight goes up by half a millimeter then the amber light gets enabled one of the other things that we could do is actually trend the data so as soon as you set the limits the upper and the lower limits so we set it as one millimetre so 153 is our normal width and then we have 152 as the lower limit and 154 is the upper limit and it trends the data anytime that the weight changes they're gonna be able to see that the current measurement is shown here and then a plot for about 30 seconds is shown there so that's about it so if you have jobs where you can do recipes you can go into this and you can start saving those recipes here so you can pick one of those and say load and then you can add those recipe there so you can say product one I want to put the nominal with - 150 millimeters or whatever that may be alarm is - warning is 1 and then you say safe so now that product 1 recipe is saved to that so if you want to load a certain recipe click on that recipe click on load it's gonna load that we go back to 1 and load that we got that whatever that we uploaded will go in now if you want to take this data and put it into your main screen you have to select that product and say accept then that will be the current value for the value so it automatically took that recipe and put it at 182 millimeters the range that we set alarms that he said automatically goes in there so since that's not the right one so let's just go ahead and load it and then put our current value there save accept and now we set our current weight to be 152 which is outside our limits so you got the amber light and then whenever you need to plot it we can plot that data right there so that's a brief overview of the weight measurement with our PLC's you

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# How to set Web Width Measurement Parameters using PLC

URL: https://r2r.tech/videos/how-set-web-width-measurement-parameters-using-plc.md

A programmable logic controller (PLC) or programmable controller is an industrial digital computer which has been ruggedized and adapted for the control of manufacturing processes, such as assembly lines, or robotic devices, or any activity that requires high reliability control and ease of programming and process fault diagnosis.



In this case, Roll-2-Roll Technologies programs a PLC, so you are able to set the parameters (or recipes) that best suite your operation for web width measurement. Learn how set up or change these recipes in your PLC in this video.

## Transcript

so in order to set up the Center for British Mint and we'll go over this menu once one more time we're going to go to the setup screen right here and then click on width setup then we can enter our nominal width the alarms the warning ranges and all those things first we want to whenever we have a new product in there we want to measure the product what the width of the product is in this case it's 153 millimeters we're going to enter 1 5 3 enter and then we're gonna set the warning to be point four millimeters so if the alarm is less than the warning the system will not accept it so the best way to do that is to make sure to set the alarm first so we'll set the alarm at 1 millimeter and there is a way for us to set a symmetric alarms so the positive range can be 1 millimeter and the negative range can be 0.5 millimeters if we want it to so in this case I'll set it at at 0.8 millimeters and then the warning range in this case let's set it to 0.4 millimeters and we have set everything what we want to do is to say hey this is the right one so we say record wait what it does is it teaches the sensor to say hey this is the nominal width we're looking for and I have presented the web with the right width and it'll take the measurement from then on so if you go back to the home screen it's going to show you the measurement and as long as it's within the range you're gonna have the green light whenever it goes to the warning limit it's gonna go to Amber and then whenever it's about the alarm it's gonna go to the red light these are actually also triggering a digital output on the PLC so we can connect a stack light with three outputs so connect the red sorry red amber and green to the three signals in the stack light the other thing that we want to point out a little bit more is the recipes so sometimes you might not see it you just have to click on this to say display recipe so what we have provided is an option for you to save seven different product recipes you can scroll through them and let's say we want to pick up product seven and we want to use that as the recipe what you need to first do is pick that number click on load and it's going to load the data here right now it doesn't have anything so let me go to one which has something ok so now I loaded product 1 and it had some values there so we'll have to load it once you load it it's loading is just for display purposes you need to press accept to accept that recipe so that it will be sent to the front screen for width measurement in this case I want to make sure to make some changes if you want to make the changes you can directly click on that width value and I'm going to enter 153 and then alarm as one date and then warning as 0.5 once I enter that if I press accept it's gonna send it to the front screen if you ever change a recipe you need to make sure to save it so right now I can press save now it saves it to the memory so that means that anytime you go back to that recipe and come back to one it will retrieve that data so make sure to remember to save it so two things one is if you want to load something it loads it here so we want to do that loads it here and if you want to take this recipe and put it into the front screen you need to press accept and any time you change the recipe you need to make sure to save it so that's the thing about recipes you have an option to say about seven recipes here there is also an option to log the data as you make the measurement there is a USB on this PLC so what you can do is you can connect a USB there and click on start logging it will it will start logging the data and whenever you're done you're gonna say stop logging and it'll stop logging the data and then you can take the USB off from there there are a few other settings here that you can set up as well these are advanced settings there is an option to override the minimum contrast in our sensor the minimum contrast is used to say whether something is an edge or not in the picture so by default we have 50 so we can have that and if you want to enforce that you need to press this button so that it changes into lime green instead of dark green whenever you want to disable you press that it disables that and this is the place where you can enter the value you can also make the sensor provide the data that is already filtered so if you want to do that you turn on the filter turn the lime green turn off the filter it goes off this is an advanced feature which is called as a minimum measurement quality whenever we take a measurement we have an output called quality factor and we can set that nominally it's ten millimeter ten is the minimum quality factor now if you want to make it higher you can set that value and enter it there so as long as there is a value it's going to take this value if you want to disable that option press n zero so I press ten and enter and it'll be that that's the minimum that you can provide so this screen is more like an advanced screen your operator wouldn't really have to do this only people engineers that are setting up the system can use this for troubleshooting purposes and stuff like that and yeah that's about it so these are the features there and like we talked about before we also have the option to log the data and showing the log of the data right here you

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# How to Setup Web Width Measurement Based on Two Contrasting Features on the Web with Two Sensors

URL: https://r2r.tech/videos/how-setup-web-width-measurement-based-two-contrasting-features-web-two-sensors.md

For a complete overview of web width measurement with Roll-2-Roll® Sensors and Roll-2-Roll® Controller please visit this page: https://r2r.tech/articles/web-width-measurement-and-monitoring-applications-and-technology

For more information about the SCU controller please visit: https://r2r.tech/products/roll-2-roll-controller

## Transcript

continuing along the lines of measuring the width of the web based on the contrasting feature in this video we're going to look at how we can measure the width based on some printing or contrasting feature on the web with two sensors so I've got a sample here with a whole bunch of features on the web not just the edge of the web the left side has a intermittent line of a certain width and then the right line right side has a solid line and then we have some labels with different edges with gradients and things like we can use any of these features to be able to measure the width of the web we don't necessarily need the edge of the web and as explained in the previous video These are relevant for certain applications where you want to measure the width of a coating or the width of a printed feature that might expand or contract differently than the edge of the web and then our sensors have the ability to be ability to do that so let's go into the controller and see how we can set this up we want to First make sure that both sensors are enabled and I've got both sensors enabled and I'm going to the operator sensor screen and we've got the sensor one and the Sensor 2 image as a first step what we are going to do is we're going to teach the teach Sensor 2 to look at that intermittent line and sensor one to look at the solid line and use that information to measure the width of the web so let's go to Sensor One sensor 1 has the solid line so we want to pick that line so I'm going to go in and pick the line mode and pick the feature that I want that's the solid feature that I want logged in on it now go into sensor 2. this is the intermittent line so if I move the web or remove the material you can see that the line disappears comes back in so I'm gonna pick that feature right there lock it in and then we have locked both the features but we don't know the distance between the two features so if we already know what the distance between the two features are then we can enter it so let's say it's eight inches is the distance between the two features I'm going to go in and teach it so the teaching procedure what it does is it teaches the controller to know that to know the distance would be in the two sensors if we don't do that then the output measurement is not it will be it will be proportional but it won't be the measurement so I'm going to go in and teach now I've got that measurement taught in as you can see on the web browser that the measurement now has updated to 8.002 inches and what I'm going to do is I'm going to move the sensor so maybe we can have a picture and you can see it there I'm going to move the sensor so that you can see how that width measurement changes oops there's the width measurement and when I move the sensor you can see that the width increased because I moved the sensor outside and now I'm going to move the sensor inside and you can see that the width goes down this way you can pretty much teach the controller to pick up any feature that you want and have the ability to track the width of the two features and teach the controller for the distance would be in the two sensors and then log the data we'll also look at how we can do the same thing with a different type of feature so we'll go into the controller operator sensor screen and then this is the intermittent line sensor so I'm gonna make sure to try to teach it to the edge of the label so I've got that label there put it on auto and I want to be able to teach that so we want to come in from this direction and pick that edge of the die-cut label there and I'm going to move this Sensor 2 and do the same thing sorry sensor 1 and do the same thing so this is the black line and this is the edge of the die cut label so we want to teach it to that want to go to that mode and pick that edge of the die cut label teach it to that teach it to that we need to make sure that this turns red and all the other features goes away that's when the controller says that the feed feature had been taught if it doesn't happen then the width will not have an output also what happens if we don't have it again if we go back and teach the distance between the two sensors so let's do that to be the same eight inches and if you go back into the web browser then you can see that's the width and if I move the sensor and you can see that on the top right hand corner if I move the sensor then the width increases or decreases so pretty much any feature that we could teach for in the contrast mode can be used to track the width of that contrasting or the combination of the contrasting feature one more thing I want to mention is that we want to make sure that the teaching is accepted by the controller if the teaching is not accepted then the width will not get recorded properly so for example if I go into the sensor screen go in here and then let's say the teaching was not accepted if the teaching was not accepted it's going to look like oops it's going to look like this even though it picked up the contrast the teaching is not accepted and if we go back to the home screen the width is going to be zero this is mainly because that in order to measure the with the contrast mode both sensors the contrast needs to be picked and thought so if we go back in and teach that contrasting feature for sensor one Sensor 2 also has that already and if you go back to the home screen you're going to see the width measurement and if you go back to the web browser you should also see that with the measurement there um that's essentially how we would set up the controller for web width measurement with two sensors and both sensors are in contrast mode and tracking a contrasting feature on either side of the web concludes our presentation about width measurement with either one sensor or two sensors with either Edge mode or contrast mode we also looked at the different outputs that we received from the controller with respect to analog digital and ethernet and with this you would be able to apply our products to a multiple different applications hope this information was useful and please subscribe to our Channel and for more information about our products and how they can be used in your application

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# How to setup Web Width Measurement based on Web Edge with SCU5 Controller using Two Sensors

URL: https://r2r.tech/videos/how-setup-web-width-measurement-based-web-edge-scu5-controller-using-two-sensors.md

For a complete overview of web width measurement with Roll-2-Roll® Sensors and Roll-2-Roll® Controller please visit this page: https://r2r.tech/articles/web-width-measurement-and-monitoring-applications-and-technology



For more information about the SCU controller please visit: https://r2r.tech/products/roll-2-roll-controller

## Transcript

in this video we're going to look at how we can set up the controller scu5 controller for width measurement with two sensors I've got a couple of sensors installed here one is 112 both of them are 112 sensors one of them is looking at the left edge of the web and the other one is looking at the right edge of the web when we are doing width measurement with two sensors what we would ideally like to have is two sensors of the same range that means that if we have a 112 here we would also like to have the 112 there and then we also want to have the two sensors with the same orientation in this case this particular sensor has the connector coming on the right hand side this is behind the web it's on the right hand side and likewise for this connector it's coming on the right hand side and that's what we need because our camera has the pixel one here and then the nth pixel here and then for here the pixel one is here and we have the nth pixel there if we have one cable coming out this way and the second cable coming out this way this camera has to be inverted which is not ideal and it will not give you the correct output now if both cameras are inverted that's fine we cannot have one camera straight and the other camera inverted and that's an important thing that we need to keep in mind when we are using two sensors so we have those two sensors one is looking at left and the other one is looking at right we're gonna go into the controller and show how we can set that up so go into the tools icon power user sensor in this case we had sensor 1 disabled so we're going to enable that and we also have the sensor one looking at the left edge of the web so we're going to set that to left Edge and we're going to set that to right Edge for Sensor 2 and then again we're going to go into the operator screen go into the sensor a Sensor 2 image is pretty solid switch over to Sensor One the sensor one image is also solid but the only thing that we want to do is we want to make sure that this automatic brightness is set to freeze and then increase that brightness just a little bit so that we have that the web position is pretty close to the edge of the sensor that's fine if you need to move it you can move it so I'll just go ahead and move that sensor back in so that we have it within the range and there we go now we can go back to sensor two both sensors have the range set properly and then next we need to make sure that the output mode is an analog analog output mode is in width again we'll go back to 10 volts for now just for measurement purposes and then that's done and the final thing that we need to do is to actually set up the um the teach the controller for the width measurement so if we go back to the setup we can see that we have two sensors and the sensors are certain distance away from each other we actually don't know what the distance between them are and the easiest way for us to set that distance is to actually teach the sensors for that distance and again for all width measurement applications we want to make sure that the web is stable and we don't have any plane change so it's supported between two rollers here so it's pretty stable and we want to make sure that we don't change that while we are running in the sense of the plane change now in order to teach the sensor what we are going to do is we're going to actually measure the width of the web so it's about eight inches wide and go into the controller here and go into the tools icon operator width and just to make it easy I'm going to go to the units inches and go to width and then eight inches is the nominal width I'm going to set that to 8 inches and then I'm going to keep the output type as absolute and now I need to go in and press the teach button and then give it a few seconds and then accept what this teaching procedure is doing is that it's taking the nominal width entered in this controller and it takes the measurement from each sensor and then it computes the distance between the two sensors that's the way in which we're able to teach the controller for the distance between the two sensors as long as the the distance between the sensors are not changing as long as we are not moving these sensors if the width changed you don't have ever have to teach it again because the teaching procedure is only setting up the distance between the sensors and and there's no need for us to teach every time the width changes this is a one-time procedure and as long as all the settings are the same then we don't have to re-teach the just like the single sensor mode if you go in to the controller we can set the output type as absolute or header so if you set it as absolute the display value is going to provide an absolute measurement and if the width increased or decreased it's going to show that value so if I put in an extra one you can see that the value increased or decreased based on that now you can also set that up to oops set that up to error and in this case it's going to provide an error output so if I add something you can see that the error changed increased and that's essentially it so few things to keep in mind when we are looking at the width measurement with two sensors so we have the sensor position indicators here so we we got the sensor one as the left sensor here and Sensor 2 as the right sensor those are indicated and we have a split screen here the left side is showing the left sensor or sensor one and the right side is showing the right Edge or the Sensor 2 the green line here is showing the center line position of the web with respect to the two sensors and then the label here shows the width and then right now is showing the error and if we want to set it to Absolute and it shows the absolute value there that's how we set up the width measurement application for two sensors and in the following we'll also look at the analog output when we have two sensors

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# How to setup Web Width Measurement with Contrasting Features on the Web using a Single Sensor

URL: https://r2r.tech/videos/how-setup-web-width-measurement-contrasting-features-web-using-single-sensor.md

For a complete overview of web width measurement with Roll-2-Roll® Sensors and Roll-2-Roll® Controller please visit this page: https://r2r.tech/articles/web-width-measurement-and-monitoring-applications-and-technology

For more information about the SCU controller please visit: https://r2r.tech/products/roll-2-roll-controller

## Transcript

hello everyone today we're going to talk a little bit more about width measurement but this is more like an advanced width measurement application one of the things that you're going to see in the industry is that different people provide width measurement based on the edge position there are certain applications where you would need to measure the width of the web not based on the edge of the web but some contrasting feature on the web for example if you have a lamination or embossing application where you have multiple layers of web and the web goes through some Heating and Cooling different layers of the web May contract or expand and this might change the width of the web and and if you're just looking at the edge of the web that may not be representative of the width change that is experienced by a feature on the web withdrawal to roll our sensors not only can detect the edge of the web but it can also detect some contrasting features on the web and will take advantage of that and with that we can also look at width of that contrast contrasting feature so we have a setup here where we're looking at a sample in the bottom right there and then we have one of our white light sensors the ODC 48 white light sensors installed there and it's looking at that sample and this is just to simulate how we would do a contrasting feature measurement application where the web is stabilized either on a backup roller or really close to a roller so that the plane of the web doesn't change and that's what that is simulating and then we have a controller here and the controller is actually set for contrast mode you can go in and you can see that it's set for contrast mode and then it's also set to provide the width as an output and we'll see how that we can set it up to provide the width output even though we have two sensors connected we have disabled one of the sensors we're only looking at One sensor in this particular sensor is Sensor 2 and it's set for contrast mode what we are going to do is we're going to measure the width of this contrasting feature right there it's hard to see in this image but there is gray region a black region and another little bit brighter gray region here as a first step we're going to make we're going to teach the controller for the feature that we want to this is very similar to tracking so if you want to track this feature you're going to do the same thing press this button to unlock the teaching mode and depending upon whatever feature that you want to pick you can scroll through it in this case we want to pick this black feature right there we have selected it the contrast mode that we have this is the line mode so we have detected that and then lock in on it and if we go to the home screen you're going to see the the contrast the middle of the contrast representing the contrast is chosen as in line mode and then it's also showing the width of that feature so if I move my sensor back and you should be able to see that the width change a little bit but it also keeps track of the position one of the things with this particular mode or line mode is that in order to lock on this contrast there are two conditions that needs to be met one of them is the width of the contrast and the other one is the color of the contrast or the brightness of the and this is intended to make sure that we don't jump from one to another contrast and if you are measuring the width with this particular feature then whenever the width changes too much or the color changes too much you're going to have the measurement you're going to have no measurement what I mean by that is if I go in here and then pick the next line this is still a black line but you can see that the width went to zero even though there is a black line that you see here that's because of it it lost that contrast measuring the width of the web based on this contrasting feature is restrictive in line mode however we can go in and measure the contrast with in in other modes for example if you want to look at this particular width so this is the width of this region that you want to measure you can select that teach it then go to the home screen and that's showing you the width of that region and if we reduce that width you can see that that this region is 0.68 inches and then if we move further and further that region increases and it'll go all the way up to you see any other black region and now this is the measurement of the width the contrasting feature width and if we move any further the width is not going to change because it's bound by from this region to this region so we can not only measure the edge of the width of the width based on the edge we can measure the width based on any of the contrasting feature in the web so this is with one sensor how we do it some examples of applications is to measure the width of a die cut edge of a label to the edge of the web this is important in slitting certain slitting applications require the edge of the web to be at a certain distance from the die-cut edge of a lab or edge of the web to be at a certain distance from the edge of a printed mark on the web other applications are to measure the coding width in any type of coding or glue width or any of those kind of things lithium ion battery trim width measurement or tab width measurement or some other examples of this application where you want to measure the width of a contrasting feature the outputs that we provide is going to be very similar to the edge outputs so in this case we are using a 48 millimeter sensor and then this value is or we are using about two inch wide sensor and this value is about 0.68 inches so the output if it's an analog it's going to be proportional to the width of the sensor and again you can also get this output through the ethernet and if we look at that on our web browser we should also see the same output so again if we look at the output on our web browser it shows 0.685 inches and if I move the sensor and the width changes it updates that value again you can do it in millimeters if you want that's 21.7 millimeters or in inches it's 0.805 0.855 millimeters okay so that's a quick overview on width measurement based on a contrasting feature on the web with just a single sensor in the next video or in the subsequent video we will take a look at how we can do width measurement with two sensors based on the contrasting feature on the web

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# How to setup Web Width Measurement with SCU5 Controller using a Single Sensor

URL: https://r2r.tech/videos/how-setup-web-width-measurement-scu5-controller-using-single-sensor.md

How to setup Web Width Measurement with SCU5 Controller using a Single Sensor

## Transcript

hello everyone today we're going to look at we're going to look at how do you measure width of the web with just one sensor we have some videos in our website about this but in this video we're going to look at a few different things one is the teaching procedure there is a small teaching procedure that we need to do whenever we are doing a width measurement and then we're also going to look at different output options that we have from what we have is a sensor that is connected to our seo5 controller and and the controller showing the width of the web and we'll go over how we set these up and also get the output from the controller first and foremost depending upon the application in this case we are looking at width of a web with one sensor so we need to make sure that we have those set properly go into the tools the power user sensor Sensor 2 is the one that we are looking at and now one is set to Center mode if we use One sensor and we need to look at both edges of the web Center mode is the way to in the following videos we'll talk about two sensors and how do we use two sensors for width measurement but with one sensor we need to have the sensor set up in sensor mode Center mode and then we go in and make sure the image is looking good this screen just provides us a real-time preview of what the sensor sees and it allows us to set some of the parameters for the image capture one of the key things for width measurement is that the web needs to be stable so in this case web is supported between two rollers so that the plane of the web doesn't change and we want to make sure that the plane of the web doesn't change because this is essentially a camera when the web moves farther or closer like what I'm showing right now it will change the width measurement just because of the fact that the image is going closer or farther away or the image is in Focus or it loses focus and that is not ideal for us and as you can see if I have the web move farther and closer you can see that the image is changing we don't want that image to change ideally we want to have a solid image like that this is a good image and this is not an Ideal Image anytime we do width measurement we need to make sure that the plane of the web is stable the best way to do that is to install the sensor between two fixed rollers that's what we have in the setup here and then that way we can take care of that that's the first thing for the width measurement application is that we don't want to measure the width of the at the exit of the web guide because at the exit of a web guide the corrective action of the web guide is going to change the plane of the web and we can measure the width but that's not going to be accurate to 5 000 of an inch like what our sensor can do that's the first and foremost thing that we want to do and if we go into the controller and the main thing that we want to set in this screen for which the measurement is set the brightness so that we have a pretty solid image make sure that the plane of the web is stable and we also want to make sure that the brightness is Frozen for width measurement and the main reason for that is when you set it in automatic brightness I'll just show you it kind of picks up sting features the algorithm that is used to do that is not only looking for a certain image but also looking for certain things within the image that's not ideal for us ideally the easiest way for us to do it is thread the web have some tension put it in automatic brightness freeze the brightness and increase the brightness just a little bit so that you don't see that any more lines in between so you want to see a solid image like that and that's what we want to do once we have this set up like this now we can go into the analog output mode to make sure that the analog output is in width measurement and we can go in once that is done we have the web stabilized we have the brightness set to a certain value we have made sure that the analog mode is in width now we are ready to teach and that can be done in the operator menu so we go into operator and go into the width so the main reason why we need to teach the controller for the right width is because we might have set the plane of the web at any arbitrary location we might have changed the brightness to any arbitrary brightness all of these effects the the accuracy of the width measurement and anytime we change any of those settings we do need to teach the controller for the width and that way we are fixing all the parameters and making sure that the measurement that we are getting is the right measurement in this case I'm going to go in to teach the sensor or the controller for the right measurement ideally ideally we want to measure the width of the material and whatever that value is we're going to put it into the nominal width in my case right now I think this is about 65 millimeters so I'm going to set it to 65 millimeters right there and approximately 65 millimeters and we're ready to teach when we are all that we need to do to teach the controller is that we're going to press this one button and give it a few seconds and then press accept what it does is that the controller is going to take that picture computer width of the web it sees and however long you're waiting it's going to take an average of those measurements and then once that is done and when once you press accept it's going to compare those average and what the nominal width is and it's going to create an offset or basically a calibration and that's how we know what the right width is and from now on that's going to be the width output as long as the settings don't change this is a one time basically one-time procedure you don't have to come back here and do it every single time that's about it so now the sensor is calibrated for the required width and if we have the web width change a little bit you can see that effect there on the controller output so if you have the width change let's say I introduce something here and you can see that the measurement is providing the output it is providing so that's as simple as it is to set up the system for width measurement with a single sensor like I said the thing for width measurement is that we need to have the web State the web can be at a certain distance anywhere from quarter inch to maybe half an inch but while the machine is running we don't want that distance to change at all and that's because of the focus thing that I mentioned one other thing right now all the units are in millimeters if you want to change the units on these you can go into the tools icon operator display and then change that to inches so you should be now able to see the values in inches and then when you teach the web again all of these values are again in inches that's for teaching the system for One sensor one other thing that we can look at is the output that is displayed here that's the width of the web there are some applications in which we don't really care about the width of the web we want to see how much is the web width different from its nominal width and that's pretty easy for us to do all we need to do is go into the tools icon and then press the operator width and then the output type instead of saying absolute we're going to make it as error and now if you go back to the home screen this is displaying the error in the measurement this is basically 15 thousands of an inch and again if you want to look at that in millimeters that's about 0.381 millimeters so you can either look at the actual width or you can look at the absolute width with this system anyway please subscribe to our Channel and take a look at other videos that we have on how to use our products and how it can benefit your application thanks

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# How to Upgrade a North American Web Guide - H5533 Actuator Replacement

URL: https://r2r.tech/videos/how-upgrade-north-american-web-guide-h5533-actuator-replacement.md

Converters can save money and time by installing a North American Web Guide Upgrade kit from Roll-2-Roll Technologies.



In the video we demonstrates the replacement of the actuator on an old North American Web Guide as part of the upgrade process with Roll-2-Roll® Web Guide Upgrade Kit, with controller, sensor and actuator.



The video shows step by step the process of removing the existing actuator and replacing it with a Roll-2-Roll Technologies actuator.

## Transcript

we're retrofitting our north american h5533 actuator wider web guides might have this cam roller smaller web guides may not have these two extra supports this is the pivot pin in the back of the webcam there's also a spring washer right here all these now we should be able to remove the top off that's what is inside so it should be a set of bearings here there's a washer right there the back of this we're going to have some needle roller bearings so let's just take them away and put it on right here and let's grab these doors uh bearings for me to grease them you need to grease them that's about it these two are the supports on the either side we'll just use them later on okay and we'll leave this in place here this is where the actuator is mounted okay so this is the old mechanism that they have there's a motor that's driving a pulley there's a gear reduction there and that pulley is actually connected to an even smaller pulley driving another pulley that's driving a lead screw so pretty complicated kind of mechanism when we go over our retrofit we'll show you how this is being simplified with our system we do not need to save any of these drive mechanisms because we're going to completely replace it with our actuator so well there's some more pretty small motor for a pretty big web guide actually now what we're going to do is remove the lead screw and in order to do that we need to remove this right here as you can see it's got threadlock red on it so let me put it back we'll try to make sure to put the same kind of red on it there's a small cover to the leech from the back so we're going to remove that and this is a spring which is used to cover the lead screw so that the dust and dirt doesn't go in uh the spring seems to be in pretty good shape so we're going to reuse it for a retrofit this is the old mounting recirculated ball bearings and basically you had the lead screw with the reach circulating ball bearings in it it does require some lubrication and stuff like that but we're going to go to a different kind of an actuator where the lead screw doesn't need to be lubricated [Music] just put it back in i'm going to make sure that this is smooth in this case it is not so we're going to take it apart and make sure to clean everything on this and see if we need to replace those bearings in there if not we'll just uh leave it as it as such and then put our actuator in there so this is the linear raceway mechanism seems to be pretty smooth just wasn't aligned properly here so when we put it on we make sure that it's well aligned when we install it and then make sure that this moves freely and then we'll put our actuator in these things on the end right here there are basically stops so that would limit the web guide from moving all the way through the raceway and stop at these tops these can be adjusted based on your need but for now in our case we're just going to keep it as it is and install the other things this is the servo center sensor right here we will replace it with our sensor so we don't need this one so we wouldn't need any of these let's see the other thing with these web guides is that they have this pivoting mechanism right here so when the actuator moves in and out in order to make sure that the geometry makes the web guide move along the rail uh you need some pivoting and that's why we have this in this part right here seems like it's a little bit tight so we're going to take it apart and check everything and then put back everything so that we can make it run smoothly again these are all needle thrust bearings so a couple of layers of them with the spacers in them that makes it easy for this to move so it does seem like just the just the tightness of this was not making it move properly so when we put it back in we'll make sure to tighten it appropriately so that it's not hard to move okay again we're retrofitting our north american h5533 actuator so for this particular actuator we have a mounting with our actuator and just a pivoting rod that basically holds the carriage so we have that so when you're ready to purchase the retrofit kit we'll supply an actuator with the appropriate lead screw stroke length and everything so that you can retrofit this one so let's go ahead and do that this would be facing this way and let's put these rods in [Music] the only additional thing is that these were the shoulder bolts that you removed unfortunately it doesn't fit in with our mounting bracket so we would supply a spacer with a longer shoulder bolt on it and we will use that to mount that onto the system right there and let's go ahead and get this finished and that's about it so do not forget to put the bearings these bearings need to go in here we check them out and these needle roller bearings seems to be fine so we're just gonna put it right there and put this one this one goes right here with this nut so right now just to show you more or less the final application or all the connections already completed we're just going to show you that we can jog already with our control we can jog our our motor in position furthermore if i just place my hand to use as a material a possible material i'll just put it in automatic and you can see how it moves the whole thing so there you go it's a pretty uh easy setup for us so if you have an old web guide such as a north american and you want to do a retrofit this is we can provide you with a retrofit kit you can either install it or in some cases you can send us a web guide to us and we can do the retrofit for you you

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# How to Use Different Sized Sensors for Center Guiding with the SCU6x Controller

URL: https://r2r.tech/videos/how-use-different-sized-sensors-center-guiding-scu6x-controller.md

In this video, we explore the nuances of using different sized sensors for center guiding in web applications with the SCU6x Controller. Normally, it’s recommended to use two sensors with the same measuring range and resolution to avoid confusion. However, this video demonstrates how it's possible to use sensors of varying sizes and addresses the potential confusion that may arise. You'll learn about sensor configuration, including how the screen displays information when different sensors are used, and how the web position indicator operates. We also cover key aspects such as sensor orientation, web position indicators, and web detect signals.

00:00 Introduction to Center Guiding with Sensors
00:20 Using Different Sensor Sizes
00:36 Configuring Sensors and Screen Display
01:20 Understanding Sensor Confusion
02:08 Conclusion and Key Takeaways

## Transcript

one of the things that I want to point out is that in uh normal situations we will always ask that uh when you do Center guiding with two sensors that you use two of the same sensors with the same measuring range and same resolution it just makes it easy and it avoids any confusion here I just wanted to show that it's possible to use different sizes of sensors when you do centering uh what where does this confusion come from just to show on the screen what I mean by that we have one sensor configur to left and the other sensor configur to the right and when we do that the screen is going to be split up into two regions or the web position indicator is going to be split up into two regions if I present the web on just one sensor so I'm presenting it on sensor one which is config as great sensor you can see that only that great half is being updated likewise only the left half is being updated and then when I have a web wide enough it sees both sensors then the portion of the left half corresponding to the left sensor and the portion of the right half corresponding to the right sensor is only going to show up there so the confusion arises mainly because we have one sensor that is almost six times or or eight times wider than this sensor but we only have the same 50% uwing area on the top so when we move just a little bit on the bottom sensor it seems like it's moving a lot whereas when we move little bit on the top the the right left sensor then it seems like it's moving a little but in reality it's moving the same amount but it's just that on the screen we don't have we're not scaling that based on the two different sensors range so that's the difference so we covered the main things with the sensors in terms of the orientation how the web position is indicated how you get the web detect signal and things like that

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# Importance of Sensors in Web Guiding Systems

URL: https://r2r.tech/videos/importance-sensors-web-guiding-systems.md

In this episode of our webinar series on web guiding fundamentals, we dive into the critical role of sensors in web guiding systems. Learn about various sensor terminologies such as range, resolution, accuracy, and linearity, and understand the importance of accurate measurement for effective control. We discuss different sensor technologies including infrared, optical, and ultrasonic, and explore the challenges they face including issues with temperature drift and material properties. Discover why precise sensing is essential for guiding performance in web handling applications.

00:00 Introduction to Web Guiding Sensors
00:21 Key Sensor Terminologies
00:45 Challenges with Ultrasonic Sensors
01:09 Importance of Sensor Characteristics - Range
01:39 Resolution
01:59 Accuracy
02:17 Linearity
02:52 Types of Sensors and Their Applications
04:03 Material Dependency and Calibration
04:22 Overview of Advanced Sensor Technologies

## Transcript

[Music] One of the most important parts of a webg guiding system is the sensor. It is important because what you can't measure, you can't control. If you have a poor sensor and you're not able to measure the position properly, then there's no way that we can get the accuracy that we need. In terms of sensor terminologies, range, resolution, accuracy, linearity, those are some things that you would see.

type of sensors, infrared, optical, ultrasonic, air type of things that you're trying to look for in terms of web position. Are you trying to look at edge of a web? Are you trying to look for a line on the web or a contrasting feature on the web? How fast can the sensor measure?

Older ultrasonic sensors have issues with past line changes. You can't have the web too close to the ultrasonic emitter because it might reflect the sound waves in a way that doesn't provide an accurate measurement. And then temperature drift. Again, ultrasonic sensors can have issues with temperature drift when we have the P2 electric crystal frequency changes.

And then what kind of a signal output that you get from the sensor. Range of a sensor is the maximum lateral displacement the sensor can measure. Most often for web guiding applications, range is not that important just because of the fact that you're controlling. You're going to bring it in.

But it does becomes critical when you have web width changes and things like that. Most often range is like how much change in the lateral position that you can measure with the sensor. Resolution is the minimum lateral position change that the sensor can see. So if you want to guide a web to 5,000 of inch, then you better have a a sensor that can have 4x or 2x higher resolution than the guiding accuracy.

Accuracy is an indication of how close the sensor measurement is to the real measurement. This becomes important for certain types of sensors affected by materials. Material properties like opacity, porocity and things like that. This is an important characteristic of a sensor.

Linearity is like what how consistent is your measurement with respect to the actual position across the entire range of the sensor. In terms of sensing, why is it important? Some sensors have issues with material properties like opacity, porocity or reflectivity or they may be affected by environmental issues such as air flow, temperature changes or vacuum. So if we can't measure, we can't control.

That's why sensing is an important part of guiding performance. Most often you would see these type of sensors we refer to as opposing beam or fork style or horseshoe style. There are lots of different names for it. Basically how this works is you have one arm emitting a certain type of signal and the other arm receiving that signal and then the web that goes in between blocks it.

It's a simple technology work sensing principle and it works well for a lot of different cases. The problem happens whenever depending upon this type of sensor signal that you have if the web allows that signal to leak through when it's blocked by the web that's where the pro problem occurs. We talked about linearity resolution range all of those things are affected by this kind of sensor. This sensing signal can be air, optical like visible light, infrared lights, or even UV light.

It could also be sound like ultrasonic. It really doesn't matter. And then whether this material is opaque or porous to that signal is what matters in terms of how well you can guide. Often manufacturers recommend different sensors for different materials and conditions.

So you will have a plethora of sensing technologies out there. Like I said, the main disadvantage is material dependent gain change occurs and then requires calibration if you want to get a really good guiding performance. There are other sensor technologies out there like ours which are not affected by material properties and some of the environmental conditions. I'm not going to go into detail about our sensor technology here but just give you a quick overview.

is basically a high accuracy direct measurement or absolute measurement. Our resolution does not depend upon the range and it can work with any material. [Music]

---

# Importing SCU5 Add on  Instructions into Rockwell Studio 5000 System

URL: https://r2r.tech/videos/importing-scu5-add-instructions-rockwell-studio-5000-system.md

This video shows how to import the SCU5 add-on instructions in Rockwell Automation Studio 5000. With the add-on instructions the use can easily parse the data from the SCU5 controller and can readily get up and running with the SCU5 controller.



The different versions of the add-on instructions are available on our website here:



👉🏻 Rockwell/AB Add-on Instructions for SCU5 C(E)D/MC(E)D controller v3.5d: 🔗[https://r2r.tech/documentation/rockwellab-add-instructions-scu5-cedmced-controller-v35d](https://r2r.tech/documentation/rockwellab-add-instructions-scu5-cedmced-controller-v35d)



👉🏻 Rockwell/AB Add-on Instructions for SCU5 C(E)D/MC(E)D controller v3.6c: 🔗[https://r2r.tech/documentation/rockwellab-add-instructions-scu5-cedmced-controller-v36c](https://r2r.tech/documentation/rockwellab-add-instructions-scu5-cedmced-controller-v36c)



👉🏻 Rockwell/AB Add-on Instructions for SCU5 C(E)D/MC(E)D controller v3.6g: 🔗[https://r2r.tech/documentation/rockwellab-add-instructions-scu5-cedmced-controller-v36g](https://r2r.tech/documentation/rockwellab-add-instructions-scu5-cedmced-controller-v36g)



For more information about the SCU5 controller please visit 🔗[https://r2r.tech/products/roll-2-roll-controller](https://r2r.tech/products/roll-2-roll-controller).

## Transcript

hi this is Carlo from Roseboro technology and today I'm going to show you how to import our add-on instruction to be used with our su5 controller first of all let me show you my setup I have my Rockwell PLC over here I have an su-5 controller over here and I have a sensor over here that we will use for testing and here on my studio 5000 I have already added my su5 controller over here and you can watch our video on how to do that and now I'm gonna import our add-on instruction to be used with the su5 controller I'm gonna head to our website rolltrol.text slash documentation and I have selected support file over here and I'm gonna look for the Rockwell Automation add-on instruction I'm gonna do right click save links as choose the folder where I want to save my add-on instruction save then heading back to Studio 5000 we're gonna go on add-on instruction right click import that on instruction go back to the folder where I downloaded the add-on instruction select the add-on instruction click this if you want to change the name you can change the name here otherwise I'm gonna go ahead and say okay and now I have the add-on instruction added over here and then all the user defined variables are over here then I'm gonna go over and to my program or wherever I want to add the add-on instruction look for the add-on extraction over here and SEO five add-on instruction click the add-on instruction gets dropped there now I have to Define the variables for my add-on instruction I'm gonna call it su5 then I need here I'm gonna have to link the input and output variable for the add-on instruction to the input and output variable of my controller in this example our controller is called demo and this is the variable I need to link and then the output variable into demo this one and this variable the name of this variable will change depending on the name that if you go into the io3 the name of the SEO file controller that you want to link the aoi tool needs to match this input and output variable over here and now I'm gonna create the variable for the output of the aoi I will call this demo to sensor one and the from variable are variable there are reading data from the sensor while the two variables are that are used to control the sensor and I'll do the same for sensor 2. demo from to name two minimum this variable is used to control the brightness of the sensor and for the web guide the same concept the from variable are data coming from the web into the plc and two variable are demanded actually control the webcam okay now I need to add all of this variable so I'm gonna do right click Nemo I will leave all of these to the default value create I repeat that for all the variable create here I have named all the variable if you still get an error over here most likely you have forgotten to create one of the variables in this case I did that on purpose I forgot to create this one and now once everything is in order you will have no error and you also if you look at project variable you will have all the variable from that you have created over here and each of these variables have meaningful feel that you can use to either read data from the sensor like if the sensor is present low contrast in a web and all of these or the the sensor position The Edge position and all the data coming from the sensor okay now I'm gonna download this project and try to see the data coming from the sensor and make sure that everything went well in my aoi so I'm gonna go over here go online and I Do download I'm online I'm in run mode everything is okay the i o is okay which shows that there is a good connection to the su5 controller now I can verify that the data is coming through properly and I can already see that sensor 1 shows no sensor zero which means I have a sensor connected I don't have it in front of the sensor so it shows me low contrast and the web now I'm gonna put my pen in front of the sensor and I can see the data changing and I have the position of the pen over here changing so everything is working and this is the data coming from the sensor now if we want to control the sensor we will go to the two and one thing that it's important to know that this through this variable you can enable and disable the sensor so right now we have a sensor that is enabled in the controller and you can see from the green box over here in the controller but if I put a zero in this field over here and press enter this will disable the sensor so if I go back to this controller now you see the sensor has been disabled one thing to notice is you don't want to this to zero you is better you have to choose a value put it as of known and the values that you can choose are if you go over here and over here it shows you all the possible value that you can choose for this just remember not to leave it as zero otherwise the sensor will be disabled now you can also control the orientation of the sensor to do that you have to set this field as a one and now if this is a zero I can go in my SEO file controller and see this is a left controller if I change that field to two is going to switch to a right controller over here and if I switch this to three is going to be in Center mode here on the controller and if you go over here and over on top of the description it will show you all the options that you have for that value now common mistake that we have seen one is to name this variable for sensor 1 and Sensor 2 with the same name this will cause the aoi to overwrite the value and you will only see the the values from Sensor 2 most likely and other things is no matching the version of the aoi with the version of the controller so the version of the aoi will be shown either here or in the aoi menu over here and you have to make sure when you go into the controller you have the version of the controller over here you want to have a version of the aoi that is the closest to the version of the controller that you have and always a version of the aoi that is below the version of the controller one other problem that we have seen is that if you say you have installed their older aoi and you want to upgrade to a newer aoi it's always best to delete the older aoi and delete all the user defined variable and install new aoi from scratch rather than trying to upgrade a newer aoi the older one already installed on the system and these covers all that I have for today thanks for watching and if you want to stay up to date with all of our videos please subscribe to our Channel down below and have a good day

---

# Introducing KOIOS Analytics at LabelExpo America 2016

URL: https://r2r.tech/videos/introducing-koios-analytics-labelexpo-america-2016.md

KOIOS is an intelligent data analytics system that can detect issues in the process using the data from ARIS Web Position Sensor and Web Guiding System.

---

# Introducing ODC 960

URL: https://r2r.tech/videos/introducing-odc-960.md

Roll-2-Roll Technologies is proud to announce the introduction of their latest product, the ODC 960 sensor. Boasting a sensing range of 37.8 inches and a resolution of 0.005" or 0.127 mm, the ODC 960 sets a new industry standard for wide-range sensors, providing unparalleled precision for converters seeking the utmost accuracy in their converting applications.



The innovative Roll-2-Roll® Sensor technology mimics camera-based systems, offering superior measurement accuracy and resolution. Combined with the user-friendly Roll-2-Roll® Controller, the system delivers a streamlined, easy-to-use solution that any operator can manage.



One of the ODC 960's most notable features is its one-sided sensor design, allowing for installation near or on a roller. This unique configuration provides multiple benefits, including web stabilization, air removal, and a compact footprint that fits easily into tight spaces, minimizing the risk of sensor damage from threading errors. The one-sided design also enables downward-facing installation, leveraging gravity to reduce dust accumulation.



The ODC 960's modular design integrates the light source, optics, and 1D camera within a compact profile, facilitating close web installation and enhancing measurement resolution and accuracy. This design eliminates the need for external lighting, gantry construction, and long working distances typically required by conventional camera solutions.



Furthermore, the ODC 960's linear optics deliver 1:1 magnification with higher resolution, mitigating lens distortion or aberrations commonly associated with circular lens optics. The camera's field of view does not affect the measurement resolution or working distance, offering unparalleled accuracy and precision to engineers and technical personnel.



Roll-2-Roll Technologies' President, Aravind Seshadri, shared his thoughts on the new ODC 960 sensor: "Our customers consistently request wider sensors, as they enhance operator safety by eliminating the need for manual repositioning, reduce operator errors, and save time. We're proud to offer this highly sought-after feature while maintaining exceptional resolution even at such an expansive sensing range." Seshadri also highlighted the versatility of the ODC 960, stating, "The applications for this sensor include web guiding, web width measurement, thread/elastic counting, strip width measurement, flag detection, splice detection, and many more."



Roll-2-Roll Technologies will unveil the ODC 960 at the Converters Expo show in April 2023, where they will showcase their full range of web inspection and control solutions at booth 11. The Converters Expo will take place at Lambeau Field in Green Bay, Wisconsin, on April 13th, presenting an exciting opportunity for attendees to discover the latest advancements in web inspection and control technology.



Roll-2-Roll Technologies is committed to providing exceptional customer support and service for their products. With an experienced team of engineers and technical staff, the company offers comprehensive training, installation assistance, and ongoing support to ensure customers can fully leverage the capabilities of their products. This commitment to customer satisfaction has positioned Roll-2-Roll Technologies as a trusted partner in the converting industry.



In addition to their robust product lineup, Roll-2-Roll Technologies is dedicated to continuous innovation and development. The company actively invests in research and development to stay at the forefront of the industry, ensuring that their customers benefit from the latest technological advancements in web inspection and control solutions.

## Transcript

Hello everyone, this is Aravind Seshadri  from Roll-2-Roll Technologies. Today we   are really excited to talk about one of our newer  products for edge guiding, sensing and different   applications. We have our ODC 960 this is one of  the widest edge sensor that is available in the   resolution of 5 thousand's of an inch and this is  one of the higher resolution cameras that we have   for such a wide sensing range. There are lots  of applications for this including web guiding,   width measurement, thread counting, flag  detection, splice detection.

Some of the   unique features of this system is that it is  a one sided solution. So when you have a one   sided solution you don't have issues when  you are trying to install it in a compact   space. Becasue if it is one sided you can install  it vertically or you can install it facing down   so that you don't have to worry about the dust  accumulation on the sensor. It also occupies a   This is an unique and proprietary technology  where we have our linear optics.

This allows us   to install the sensor really close to the web. So  even though the field of view is pretty wide. You   don't have to worry about trying to have a large  working distance. We don't have that issue.

And   also because we have the linear optics we have a  1:1 magnification ratio. That means that we have   a really good resolution in terms of the image  that we are capturing. If you compare that to   traditional machine vision system with a circular  optics, when you increase the field of view your   resolution goes down. In our case our resolution  doesn't go down.

Right now we have plugged it up   with our SCU5 controller where you can get about 5  thousands of an inch resolution. This can be used   any of the applications we already support. Anyway  we are introducing this at the converters expo   show 2023 in Greenbay. And it should be available  this summer for purchase.

Take a look at our   website and we will have more information about  the sensor and feel free to contact us. Thank you!

---

# Introducing WPS 900 at Converters Expo 2020

URL: https://r2r.tech/videos/introducing-wps-900-converters-expo-2020.md

Roll-2-Roll Technologies would be introducing the WPS 900 sensor, one of the widest sensors that in the market. With over 35 inches of sensor range, this is one of the widest edge sensors, if not the widest in the converting industry. Please come visit us at the booth to find out more.

---

# Line guiding demo with compact web guiding system at InfoFlex 2016

URL: https://r2r.tech/videos/line-guiding-demo-compact-web-guiding-system-infoflex-2016.md

The line guiding capabilities of the compact web guiding system is enabled by the ARIS web position sensor as shown in this demo video.

---

# Low Profile Web Guides

URL: https://r2r.tech/videos/low-profile-web-guides.md

Roll-2-Roll Technologies is bringing you the latest in web guiding technology. Our web guides are now smaller than ever. You can have the same easy to use technology in a more compact space. Our low profile web guides require no calibration and are plug and play systems.

## Transcript

This is Pedro Velasco with Roll-2-Roll Technologies. Today I want to introduce to you one of our new products in our line of compact web guides. This is our low profile web guide, 3.5 inches tall that can go from 10 inches up to 22 inches. It's very lightweight, very easy to install, very easy to handle and it has the same capabilities that's in our compact web guide.

So having no need for calibration of the sensor, easy to operate interface for operators and you have the same quality and endurance of our compact line of web guides. The only difference is that a control unit in the control unit is placed away. You can either have with same conditions as these where we can have Ethernet IP connections, you can have analog outputs, you can have a operator icon based interface but it still has the stepper motor now which provides very smooth operation and at the same time everything that we have in our technology on the compact web guides is in this guide. These web guides are available at the end of July and we recommend them highly if you have an operation where you have very tight spaces in your line and you want to install a very reliable web guide.

So you can see more about our products at www.r2r-tech.com

---

# Nominal Width and Setting of Upper and Lower Limits   SCU6x Controller   Multiple Width Measurement

URL: https://r2r.tech/videos/nominal-width-and-setting-upper-and-lower-limits-scu6x-controller-multiple-width-measurement.md

Setting Nominal Width, Upper and Lower Limits for Multiple Web Width Measurement

In this episode of the Multiple Web Width Measurement Application Series, we demonstrate how to set nominal width, upper limit, and lower limit parameters for web width measurements on the SCU6x Controller. Learn how to adjust increments, set alarm and warning limits, and configure digital outputs to monitor width variations effectively. Whether you're manually setting up or automating through Ethernet, this guide provides a comprehensive walkthrough for optimizing your web handling processes.

00:00 Introduction to Setting Nominal Width and Limits
00:45 Adjusting Upper and Lower Limits
01:10 Triggering Outputs Based on Width Limits
01:50 Setting Alarm and Warning Limits
03:36 Practical Example of Setting Limits
04:33 Automating the Process via Ethernet

## Transcript

Then like I mentioned for each web we can set an nominal width, upper limit and lower limit. Right now I'm going to show you how we can set those things. So in order to set the nominal width we're going to press that nominal width icon and then we're going to choose how much increment we want to make. So I'm going to do 10 mm increments here.

So I'm going to change that to 50 mm. Okay. So the nominal width is 49.24. That's it.

There's no need to save anything here. Anytime you change that, that parameter is automatically saved and saved into the memory. So when you power cycle it, it comes back in. Likewise, you can set the upper limit and the lower limit.

So you choose the parameter that you want to change and pick the increment. If I do 1 mm increment that's going to be like that and you can do it like that. It's very simple intuitive way to change it. And likewise you can change those things too.

Now there are applications where we would have two types of outputs. One is to say that if my width is above a certain upper limit or if the width is below a certain lower limit you want to trigger an output there. So in those cases we would have something what we call as that upper limit lower limit kind of thing. So this is a pretty simple setting.

All that we are looking for is hey if the width goes above my upper limit trigger an output or if the width goes below the lower limit trigger another output. So just two boundaries and then within the nominal range the output is not triggered all good signals are provided. If you want an additional layer where you want to set alarm limits and warning limits then we can do that too. So in this particular case then you need to make sure that it is in alarm and warning.

When you have this in alarm and warning you have this button show up just to show you one one more time. If I have it just on upper and lower limit these are the two parameters we can enter. But if we are in warning and alarm there are four parameters you can enter. The first two parameters are here and the second two parameters are warning limits.

warning signal so that you don't have to stop the machine when the warning signal is there. This is just for the operators to know something is getting to get bad and once it hits the alarm limits then you can stop the machine if you wanted to. Just like I mentioned the warning limits are going to be closer to your nominal width and the alarms are typically farther away from there. So in this case we have it set as plus or minus.5 mm and then this is plus or minus.1 mm for that and you can do that for every single web.

You can set the upper limit, lower limit, alarm and warning limits. Right now for web two it's not set up. Web three you can see what is set up there. None of these are set up there.

But that's the way for us to set this up for the alarm and warning so that when the width changes you have the ability to provide a digital output to a stack light or something like that. So that is essentially how to set the multiple width measurement these warnings and alarms. And again just to go through this one more time I'm going to pick width two. I'm going to set that nominal width to be 49 point let's say.5 there.

So I am in warning and alarm. So I'm setting the alarm limits for this. So I'm going to set this as 1 mm and the lower one as 1 mm as well. And alarm I'm going to set this as 0.5 and 0 five for that.

And then you can keep doing that for multiple webs. And if you go back here, you can see for the different values, different webs, you see different values there. When I go from one to another, you got all of these set there. All of these are saved in the memory.

Then you have that option to do it. This is where you use the controller. An operator is manually setting this. All of this can be automated through Ethernet and you can send a recipe to our controller to say web one should be this width.

The upper limit is this and the lower limit is this. Upper warning limit is this and lower warning limit is this and so on and so forth.

---

# Normal Entry Rule - Web Guiding Fundamentals Webinar

URL: https://r2r.tech/videos/normal-entry-rule-web-guiding-fundamentals-webinar.md

Normal Entry Rule for Webs: Essential Principles Explained

Dive into the fundamental 'Normal Entry' rule for webs traveling over rollers in this episode of 'Web Guiding Fundamentals.' Understand how a web always aligns itself perpendicular to the axis of a roller's rotation, even in cases of misalignment. Learn about the beam-like behavior of the web, the dynamics of its movement, and the importance of these principles for successful web guiding applications.

00:00 Introduction to Web Alignment
00:17 Misalignment and Web Tracking
00:40 Beam Behavior and Dynamics
01:02 Transport Conditions and Static Behavior
01:26 Traction and Lateral Forces
01:44 Bending and Stress Development
01:59 Importance of Web Guiding
 

## Transcript

[Music] Normal entry is a web approaching a roller will always align itself perpendicular to the axis of rotation of the roller. As you see in this video right here, let me restart that. As soon as the roller on the left has a misalignment, the web started to track and move in such a way that it will approach the roller on the left perpendicular to the axis of the rotation. This is the fundamental principle used in most of the intermediate web guides that we're going to see.

What's happening here is that the web is essentially behaving like a beam and the angular displacement on this left hand side is bending the beam and it's causing the beam to bend and that's what is causing the web to track to this side. There are lots of dynamics involved in this process. how fast the web moves, how much does it move, all of those depends upon the transport conditions, the what type of web it is, what kind of traction you have and things like that. And obviously the static behavior is that um at steady state once this angle is set, how much is it going to move?

Are we going to see any movement on this side? As you can notice when this web moved the upstream roller, the web was still there. It was maintaining there because it was able to have enough traction so that the lateral forces or the moment that is acting there was not able to make the web move. And whenever we have a motion like this, bending occurs, bending in term means that there are stresses developed in the web.

So you're going to have a tight side and a slack side and they're going to be a tension profile here. So these are important to understand for a successful webg guiding application or execution of a web guide. [Music]

---

# North American Web Guide Upgrade Kit

URL: https://r2r.tech/videos/north-american-web-guide-upgrade-kit.md

North American Web Guide Upgrade Kit will solve your problem with trying to find parts for your old web guide.



Converting operations that have North American web guides will face issues with finding spare parts for sensors, controls or actuators. Roll-2-Roll® Web Guide Upgrade Kits for North American Web Guides are a great tool to not only save money, but also to have the future of web guiding technology in all your converting machines. Roll-2-Roll Technologies provides web guiding upgrade kits, which is an affordable solution to tackle outdated web guiding systems. Whether you want to upgrade an existing machine or experience the latest in web guiding technology on a smaller budget, Roll-2-Roll® WeB Guide Upgrade Kits are the answer.

## Transcript

alright this is better with law school rolls roll technologies we want to show you one of our applications which is retrofitting old web guides in this case we have a North American and we just want to show you really quick how you know the things that we do in order to retrofit one of the North American web guides with our controller in with our actuator and sensor so here we're showing you the assembly as we have already done the retrofit of the actuator to the web cat assembly which moves the top plate where the rollers are at as you can see here's our actuator with its a threaded rod and it's already connected to the raceway here so we have actually replaced already the rest of the components of this and the previous secretary that it had so it's a very very simple application and we provide the plates and we provide the actuator and of course we have it connected to a motor driver this is a temporary murmur of driver just for the sake of this presentation so a complete retrofit for doing this case for this guide would be the actuator which is motor driver our control unit and a sensor which depending on the application that our customer has it could be a forty eight millimeter sensor or it could be a two hundred twenty one millimeter sensor so right now just to show you more or less the final application or all the connections already completed we're just going to show you that we can jog already with our control we can jog our our motor in position furthermore if I just place my hand to use as a material a possible material I'll just put it in automatic and you can see how moves the whole thing so there you go it's a pretty easy setup for us so if you have an old web guide such as a North American and you want to do a retrofit this is what we can provide you with a retrofit kit you can either install it or in some cases you can send us a web guide to us and we can do the retrofit for you so we hope this has been of information of use to you and like I'm in before if you need any help with retrofitting an old web guide you can contact us more information you can go to our

---

# Pattern Teaching   SCU6x Controller   Multiple Width Measurement Application

URL: https://r2r.tech/videos/pattern-teaching-scu6x-controller-multiple-width-measurement-application.md

In this episode of the Multiple Web Width Measurement Application Series, we showcase the advanced pattern teaching feature of the SCU6x controller. Learn how to set up widths, samples, and jobs to monitor changes in material movement and width accurately. Discover the advantages of the pattern teaching mode, such as alerting when a web breaks and maintaining precise measurements even with intervening materials. This tutorial highlights how our system prevents measurement jumps and ensures consistent tracking of web position, making your slitting process more efficient and reliable.

00:00 Introduction to Pattern Teaching
00:18 Setting Up Pattern Teaching
00:51 Advantages of Pattern Teaching
02:20 Pattern Teaching in Action
00:00 Conclusion and Final Thoughts

## Transcript

Now we do have another feature that allows you to get even higher um uh uh insight into your process and what that is what we call pattern teaching. So essentially what we will do with the pattern teaching is that we set the widths, we set the samples, we set the job. We're looking for not only the change in the width but also change in the movement of the material. You can enable that by pressing this button that's in the pattern teaching mode.

When you're ready to teach the pattern, we're going to press this teach pattern and press accept. So now the system is taught the pattern. What is the advantage of that? If I have uh let's say I'm in web 3, right?

And if the web three breaks right now, it is actually showing you that hey, I'm supposed to see a web there. It's broken. The value is zero. And it's going to provide an alarm or alert right there.

That's one advantage of that. Another advantage with that is that let's say I have a web five that I'm tracking right here and if I have another material that comes in between there, the web five's measurement is not affected by that whatsoever. In a typical camerabased system, they're going to keep track of the width randomly based on which one is first and which one is second. That would affect the measurement.

If I do have this pattern off, web five will actually jump. You saw that it jumped to that 10 mm and it jumps back. To avoid this jump, we are going to use the pattern. And once the job is set up in your slitter rewinder, it's not going to change.

The pattern is not going to change. Then even if something comes in, that gets completely disregarded. That's the advantage with the pattern teaching or pattern matching mode. Those are the key things with regard to how you can set up our SCS 6x controller for multiple slit width measurement.

Okay, one of the thing that we wanted to show is that this width measurement right now we are in pattern mode. So even in pattern mode, if the web moves back and forth, you can see that the web is moving, but it's also keeping track of that edge position, keeping track of that width pretty accurately. And we can actually move this quite a ways off and that's when it will say that the pattern is supposed to be there, but it has moved from its intended position. So this is an example where let's say the slitter blade moves too much then you can catch that.

Obviously it'll show up in the width but it'll also show up in the web position. As soon as we come back into that location, the actual location itself, then it locks in on that

---

# Plug and play web guiding system from Roll-2-Roll Technologies

URL: https://r2r.tech/videos/plug-and-play-web-guiding-system-roll-2-roll-technologies.md

Check out this video to see how easy it is to simply plug in and use our web guiding system without any type of setup or calibration.

## Transcript

this is February Lascaux of rolls roll technologies in our series of showing you about that some features of our webcast and today we want to show you how simple it is to install the cat just to put it in operation right now we're showing you a 12 inch web guide which if we have installed in our testbench and it's a really simple it's four points where we actually fix it to the Machine and what happened the same one you're in your facility now in this case we already thread the machine the web guide with some the two and we have position the sensor where we would like to show a habit position as you can see it's a very simple sensor so it only has one face and so it's a taken away from the u-shape remember our sensors can actually detect any kind of material without having to be adjusted and now as you can see on the back side of our guide you can see that there are only two positions that we're going to plug into the first one is we plug in the sensor we have actually identified the sensor position sensor 1 and then we connect our power supply just fix it to it and if we look at the other side that as you can see the web guide reacted because it's already in operation let's go to the other side to the front and you can see our panel right here see and now it's indicating that it has located the sensor and it's ready to go and now I'm going to put this machine to work as you can see this is a very simple installation what we did let's just plug into two cables and when the key is operational come with us to Roloff acknowledges and this melts you understand more or less and how I guess didn't plug in place

---

# Pneumohydraulic Cylinder Replacement for Converting Industry

URL: https://r2r.tech/videos/pneumohydraulic-cylinder-replacement-converting-industry.md

The Pneumohydraulic Replacement Kit from Roll-2-Roll Technologies comes complete with Cylinder Replacements. We've adapted these cylinders, so they can just drop into the pneumohydraulic machines. Learn more about Pneumohydraulic Replacement Kits at https://r2r.tech/products/web-guide-replacement-kit

## Transcript

so one of the important features when we're doing a pneumo hydraulic retrofit is the replacement of the hydraulic cylinder and in this case we do that replace with one of our linear hyper actuators and we have actually prepared them in such a way that you can use them as a drop-in in place of the hydraulic cylinder now one of the main features is we can do it for any size as long as we have the dimensions that you want to do it that you want to put your the actual area in but at the same time we provided with two types of brackets on the on the back end and I bracket or you can have a closed bracket on the back end and of course on the rod end we would have a closed bracket so this is one way you can easily replace the hydraulic cylinder on your retrofit of the pneumo hydraulic system you

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# Product Manual: Unpacking

URL: https://r2r.tech/videos/product-manual-unpacking.md

Just received the latest web guiding technology? Check these unpacking instructions before you get started!

## Transcript

The ARIS web guiding system will arrive packaged in a cardboard enclosure specially designed for the web guide. Make sure you open the box in the upright position. The upright position can be verified by printing on the outside of the box. The packaging must will be enclosed in a clear pouch on the top of the box.

Use the packaging list to verify the items received. The package will include a product shipping sheet with technical information of the product and links to get online access to the product manual and technical support. Although the packaging is designed to protect the product from shock due to transportation care should be taken and handle in the box with the guide to avoid damaging the device. The sensor is shipped uninstalled from the guide at unit and will be packaged within the protective cardboard enclosures.

The cardboard enclosure is accessible after the web guide is removed from the box. Remove the protective cardboard enclosures carefully to avoid dropping the sensor assembly and remove the sensor from within the cardboard enclosure. The optional pre-wired power adapter will be packaged in the same cardboard enclosure assembly as a sensor unit if the order includes this option.

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# Replacements for Unwind Guides and Rewind Guides

URL: https://r2r.tech/videos/replacements-unwind-guides-and-rewind-guides.md

Do you have an existing unwind or rewind guide with outdated sensors and control unit? We now have a solution with our rewind/unwind replacement kits featuring ARIS web positioning sensors and control units for all electromechanical, pneumohydraulic rewind/unwind systems, providing advanced edge and center guiding.

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# Role of controllers in web guiding systems

URL: https://r2r.tech/videos/role-controllers-web-guiding-systems.md

In this installment of the Webinar on Web Guiding Fundamentals, we delve deeper into the pivotal role of controllers in web guiding systems. The episode covers the function of controllers, components such as gain, operating voltage, and sensor inputs, and explores the control structure for web guide systems, including fixed gain proportional control and adaptive control technologies. By examining open loop and closed loop responses, we highlight the importance of optimal tuning for improved performance. Advanced functionalities such as industrial ethernet connectivity and Industry 4.0 intelligence are also discussed, with a focus on achieving stability and high bandwidth for effective web guiding.

00:00 Introduction to Controllers
00:43 Key Terminology in Controllers
01:16 Control Structure and Dynamics
02:42 Advanced Control Technologies
03:31 Practical Examples and Performance
05:18 Characteristics of a Good Web Guiding System

## Transcript

[Music] The controller is the central processor that takes the sensor input, computes the corrective action and sends that information to the actuator. Nowadays, the controllers also include human machine interface like an operator interface. Previously, the controller could be standalone. It didn't really have an interface.

So the controller could be analog in the sense of electrical analog or pneumatic analog controllers. So basically controller is taking the sensor signal and then making the necessary computation so that the actuator can be positioned at the desired location. In terms of terminology, gain is one of the most common things that you're going to hear in controllers. That's basically saying how quickly or what kind of a dynamic response you need.

gain is going to do that. Other things that you're going to see is operating voltage, power consumption, whether you have a operator interface or not. And then whether this is a controller for a servo motor or stepper motor, they have drives or drivers for it. How many sensor inputs you have?

Does it have Ethernet connectivity? Does it have remote control and stuff like that? In terms of the control structure, most control systems have webguide control systems have this kind of a structure where you have a fixed game proportional control. You really don't need more than a proportional control for a web guide because there's integrator built into it.

But usually you have something like you have a motor, it might have a current loop, it might also have a velocity loop with a tachometer. Then you have a guide structure which has its own transmission ratio. And there's the web dynamic which is unknown. Web dynamics means that if you move the guide 1 mm, how much is the web going to move?

That really depends upon transport conditions, the stiffness of the web, tension and all those kind of things. And then finally, you have a sensor that measures the edge position and then it sends that to a position controller. So this is a pretty simple architecture for most webguide controllers. They are fixed gain and most often they are d-tuned because of the stability and all the other reasons.

Most web guides their controller is kind of d-tuned for the conditions. If you want to get the best out of it, you would need to retune them. The tuning has to be based on the optimal performance because the web dynamics is unknown. Most often DC motors or DC servo motors or stepper motors are used in this kind of control structure.

There are some other advanced control technologies like adaptive control where the controller can adapt or learn on the fly and tuning may not be required. When we say learning on the fly, it means that it adapts to sensor gain changes or the dynamics of the web. In our case, we have a similar structure as the one I showed first. It's still a fixed game controller, but with some motion control aspects built into it in terms of curving the position and having trajectories for velocity, we can increase the stability of the controller and provide a pretty aggressive output performance.

You can have a current loop, a position loop, if you have a encoder, and then a position of the actuator here. And finally, the web position, which includes the web dynamic. Just to give you an idea, we have a lot of different things that we can do with the controller. But the dynamics is basically if you move the this is showing a step response, openloop step response for a web.

This was like a non-woven web that we had at different speeds and see how it behaves. And you can see that when you have a step, even though it's open loop, it's trying to get there. The openloop dynamics is different based on how fast you're running. So faster you're running, it gets to that desired location uh as fast as possible.

But the slower you're running, it takes longer. Again, this is an openloop response. This is the final part of the whole web guiding, which is the dynamics of the web. Now if we add a controller to it then we can have a much better response and actually push the web guide.

In this case at the two different speeds that we were running at this was the reference change and this was the actual response of the web guide at the sensor. And then when we have another sensor installed once span downstream you can see how long it takes for that to go through. When we have a step response, we were able to get up to about 170 mm/s or like 7 in per second. This is about close to 70% improvement over an openloop response.

And again, this is closed loop. That means you're actually actively guiding the web. So with a proper control structure design, you can get a high bandwidth system close to 6 hertz or something like that and then even get a well damped system. So you can actually have an aggressive correction if you need to.

In terms of the characteristics of a good webg guiding system, it should have the ability to attenuate disturbances, easy to tune. Obviously, it needs to be stable, has good processing power so that it can process multiple sensors, have industrial Ethernet connectivity. These are for advanced functionalities. And then smart intelligence for industry 4.0.

[Music]

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# Roll-2-Roll Technologies at ICE USA Expo!

URL: https://r2r.tech/videos/roll-2-roll-technologies-ice-usa-expo.md

Visit with us at ICE USA 2019 April 9-11 Come see our new sensors! WPS 112 and WPS 220 with twice the resolution and accuracy!

## Transcript

[Music] here we are at ice USA 2019 and we're visiting and roll-to-roll technologies hey bro you wanna tell us a little bit about roll-to-roll today sure the roll-to-roll technologies were in booth one 133 at Ice Road si in Kentucky can work after year for the next two days and one of the main things that we came to do at this show was to introduce a couple of new problems now we have here our complete line of sensors from the 440 which includes already a controller to the 221 112 and the forty eight millimeter sensor now all these sensors can be you provided in either white light infrared or UV lights source now the idea for this is that any of these sensors can be used to detect any type of material you don't have to do any calibration and so it's showing what you can do as I'm showing you this mesh right here and as you can see on the panel right here it's actually detecting the material but without having to do any calibration I can actually switch to a piece of paper as you can see it detects it immediately and I can't even go as far as just detecting a piece of transparent material such as this film right here [Music] another feature that we have is we have a contrast sensor and the 48 and this one can be done in the 112 or the 221 also and the contrast sensor allows you to guide based on a contrast it can either be something as simple as considering this as a line or it can be such as a feature as a line such as leads running now what is it that we're bringing in new to the to the product line well the 112 is a new sensor that we created it's it kind of fills in the gap between the two 21 millimeter sensors and 48 millimeters sensor this can be because of customer with a request however the best thing about it is we improved the the resolution that these have they are now 63 2.5 microns that is 0.0025 inches or two-and-a-half thousands of an inch this actually gives greater accuracy better precision when you're running your line so it's all up to now getting the mechanics of the web guides to to match up to what we have in sensor precision now these are all available for either webdiver edge center guiding contrast guiding or the gathers to monitor wet widths or even it was the 440 or 321 we can actually use it to measure or to take frets count threads give information about the thread will and the averages important separation it's great for using NFC a thread and controlling system they say for example you want to monitor make sure that all the traits are there in the right position this is the sensitive that you want the Tal available with our su5 controllers now let's talk a little bit about our web guiding applications which are part of this which is the sensors are a complete part of it right now here we have a narrow web application that we're showing at a trade show and this is what we call the compact web guiding system it has a 221 on it is actually doing center guiding but I can set it up with just a touch of a button into edge guidance if necessary also if I have a white light sensor I could do it for contrast guiding so you can guy the line or a feature on your web now one of the things that we're demonstrating here today is that we really a what we call the RTI this is a PLC unit that from which we can control several web guides or several different applications including web measurement in this case this one has been set up to take our control up to six different systems in this case we have them for six web guiding systems right but we can go as high as 32 which is a great a great feature to have and all I have to do is if I want to just go right here this is actually the control panel that will be on this controller right here so I can switch if I hit the disconnect right here it will actually transfer the control to this controller right here now another thing that we want to make make our customers aware of we're not only a narrow web guiding company we also do largely replications if you miss it down the hall there's actually one of our wide web applications it's actually a unwind span that has one four systems installed in it we invite you to go just down the hall and visit and see auto applications already in machine now one of the things that we want to tell you about us is all this technology was developed about ten years ago it has been in the market for the past five years and it has been proven on on our customers applications so it's a proven technology we are the only company that can do work with any technology really no report and no required I guess no required adjustments or calibrations of them two of the sensors because of the change of maturity we invite you to come down to our our booth here at at ICU and say we're in booth 11:33 were again here all day today and all day tomorrow and come talk to us if you have a web padding application or a sensing application that you have difficulty with come to us because we are the expert

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# Roll-2-Roll Technologies Launches the 440mm Sensor 

URL: https://r2r.tech/videos/roll-2-roll-technologies-launches-440mm-sensor.md

Roll-2-Roll Technologies is releasing a new bigger and better sensor. Check out this video to learn more and reserve yours today!
  

## Transcript

Hello, this is Pedro with Roll-2-Roll technologies and we're going to talk to you a little bit of our sensors especially the array on sensors that we have available to the market now we have talked before about the WPS 48 which is a 48-millimeter sensing window and the 221 with a wider window available for a mostly center guiding and it can do edge detection as the other can and also it does you know thread counting and it can be used to monitor web width as one of the many features it has. however we're introducing to the market something we just developed in which will be available in May to the industry which is the WPS 440 IR. It includes also the same infrared signal and it has a four hundred forty millimeter sensing window but one of the best features of it all is it even though these require a sensor control unit this has a central control unit enclosed within the same package. All you have to do is connect two cables and the sensor is ready to go.

Now with this you can monitor remotely a web but the same time you can also control a web guiding system. So this is available to the market in May, we're going to be showcasing this at ICE USA 2017. We'll be at Booth 1034 and we can actually see the sensor in operation over there. So in order to get some more information about our products, visit our website the www.r2r-tech.com and see some more about our products thank you

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# Roll-2-Roll Technologies Web Position Sensor demo with multiple materials

URL: https://r2r.tech/videos/roll-2-roll-technologies-web-position-sensor-demo-multiple-materials.md

This demo video shows the capabilities of the Roll-2-Roll Technologies web position sensor to work with different web materials without the need for any setup or calibration.

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# Roll-2-Roll® Sensors: How it works and what are the applications?

URL: https://r2r.tech/videos/roll-2-rollr-sensors-how-it-works-and-what-are-applications.md

The webinar will cover sensing and measurement technology that are used in Roll-2-Roll® Sensors.



The presentation will cover:



- the fundamental working principle of the patented fiber optic technology
- how it differs from the conventional sensors
- benefits of the fiber optic technology
- application of the fiber optic sensor technology for sensing and measurement applications such as edge detection, width measurement, registration mark detection, flag detection, void/hole detection, tear detection, etc.

## Transcript

talk a little bit about the different sensors that are available in the market and how our sensor is different and then we'll also talk about what are the applications for our sensor in this industry so to start off with just to give you an idea on some of the topics that we cover most often when we are looking at edge sensing a lot of the sensors that we use are going to be optical sensors but the some of the concepts that we have covered here doesn't really only apply to just optical sensors it can also be sound or any kind of a wave so some of the basic concepts that we are going to be looking at and is what is reflection what is absorption what is transmission and how the conventional sensors use these concepts to determine the web position and while we are going through this presentation you will also have some polls that will be administered you should be able to see the pulse and if you can answer those that would be really helpful for us so that it cannot guide us through this process I also have Carlo and Pedro Manning the polls in the Q&A section so any time there is some question or things like that feel free to put your questions there and they will be able to address that so in terms of concepts let's take a look at these so reflection so we have a light source that is being incident on an object and what can that light do well basically there are three main things that can happen to the light source the light can be transmitted through the object most of the time if the material is optically transparent or translucent there is some amount of the light or radiation for that matter which actually goes through the object some amount of light would be absorbed when the light is absorbed this is mainly because the photon the photons interact with the object and they would get absorbed into the object and this may be dissipated in the form of heat or even fluorescence then some amount of light would be reflected and basically the reflection is whatever the light that is incident on the object that is returned back to the same medium that is called as reflection here the the object is usually a different medium it could be a solid it could be a liquid whatever it may be and then where this incident light is that's another different medium it could be air or it could be vacuum or any of those so the reflection is basically returning the light back to the original medium transmission is basically passage of light through the medium an absorption is actually absorption of the light into the medium the reflection and transmission typically do not change the light frequency when we say frequency it's more like color so if you have a red light and the light goes through an object or it gets reflected the color typically does not change there are special cases when it will change but usually it doesn't change and then absorption is basically the light is absorbed into the material and sometimes the absorbed light will actually change the state of the material and it can cause further emissions and those are called fluorescence these are something that you would see with ultraviolet light source and when they fall on a certain type of object the object actually absorbs the light in the ultraviolet frequency range then that absorbed material gets to an excited state and then that emits a light in a different frequency usually called fluorescence so most sensors use or most optical sensors use these these three phenomena to kind of figure out how to detect the web so actually how it happens is is based on the amount of light that is transmitted or reflected or absorbed and there is a term for those and that's called reflectance which is the ratio of the light reflected to the incident light transmittance is the ratio of the transmitted to the incident radiation and an absorption is the ratio of the light absorbed to the incident radiation the reflection reflectance and transmittance or usually used to define optical properties of material so if a material is optically transparent that means that it transmits a lot of light through the object or it also reflects a little bit of light through the object that's what it means to be an optically transparent material while on the other hand if a material is opaque that means that the the object is going to reflect most of the light and it's going to transmit very little if not none of the light that is falling on the object so most often I mean almost all cases the color that we perceive on an object is because of selective absorption so if you see an object to be green that means that that object absorbs all bay links of light except green which is reflected out and that's why we are able to see the object at screen now all of these depend upon the wavelength of light certain objects behave differently based on the wavelength of light a great example is x-ray which is also a radiation x-ray may pass through opaque objects which are opaque the visible spectrum but are actually not opaque in the x-rays wavelength like wise and transparent object may not really be transparent in a different wavelength such as an infrared that's one of the reasons why our infrared sensor can even work with transparent webs transparent materials so these are the basic concepts in terms of how light interact with an object or what happens when light falls on an object most sensors use this principle so this is one of the most common sensor used in edge detection and it's called an opposing beam sensor essentially what it is is that the sensor has got two sides to it a transmitter and a receiver the transmitter sends some kind of a signal could be light sound or it could even be air just for our case we will just limit it to light and sound and then the receiver and in in the end and that signal is being transmitted or absorbed by the material and then the remaining signal falls on the receiver so this this technology or this sensing principle works well when the material absorbs the light or the signal like what we have shown here so none of the light sources that is falling on this web material is actually transmitted so you can basically infer the position by looking at how much light that I get or let's say if the receiver gets 50% of the light then it means that the web is at 50% of the viewing area that's where it is it's really simple sensor technology and usually it's also referred with different names it's called fork-style or a u-shape sensor or a blocking and unblocking sensor technology now like I said most often this sensor technology works but there are some cases when it does and work well and as you can imagine whenever the web material starts to have high transmittance then the signal is going to leak through it and the sensor will provide a different output now if you compare these two web materials they are exactly at the same location but because of the properties of the material you're going to have different transmittance and that really affects the sensor output and that's the main shortcoming of these types of material now how does it how does it involve how does it relate to our cases basically if the material is porous that means that actually there is no solid there to prevent that light to go through or sound to go through then that's a problem obviously if it is opaque sorry um the opacity is lower then that's a problem and this means that the sensor requires calibration and since this is an inferred measurement let's say you are you get 50 percent signal that means you assume you're at 50 percent location this is not an absolute measurement so you really don't know unless you calibrate it what the actual position is and it's not accurate that's the main thing with it there's also ambiguity in spatial ambiguity with this kind of a sensor sensor technology I'll talk a little bit about it in the next slide about what what I mean by that now there are other types of sensors that try to avoid the issue with transmittance and the way they do it is what is called as a retro-reflective sensors you have a transmitter and receiver on the same side there is no receiver on the opposite side the light is now incident on the reflector the reflector is a special material so it reflects the light back to the receiver and when we do that the portion of the light that goes through the material is attenuated here and then it falls on the reflector and now all the light that is falling on the reflector is reflected back to the receiver and the light that actually goes through the material it's actually attenuated twice as much as if you had a transmitter and receiver on these two sides so the main advantage with this kind of a system is that you are essentially doubling the or essentially reducing the transmittance by half by making your light go back and forth twice through the same material so if you have like an clear material you might be able to do this where you can increase the sensitivity of your system and then you can you can use the retro-reflective technique to detect the web the other advantage of this kind of system is that the transmitter and the receiver are on the same side and then the reflector could be much farther away from the transmitter and receiver so that essentially make this like a one-sided system and this has other advantages in terms of like you don't have to have a constrainted fork where where the the throat of the fork you don't have to worry about that if the web plane changes and things like that and it's usually compact most often these retro-reflective sensors are used for in presence/absence detection and there are some sensors that are used for nonwoven applications and they actually use a special mirror kind of a thing so that it can go through low basis weight nonwoven a couple of times before we can get the signal back so that's a retro-reflective sensor now the main thing with the conventional ed sensors is that it's a simple sensor technology when you have low transmittance but as soon as you start looking at materials that have special properties and things like that these sensors have issues especially with engineered materials like nonwovens and and some really clear material the material properties affects transmissions and absorption and hence the accuracy of the sensor is lost now I talked about spatial ambiguity let's say the receiver is a single element maybe it's an ultrasonic receiver with just a one element or maybe a photocell if that's the case then if you have a small object like this which is much smaller compared to the viewing area of the sensor and if the object is anywhere within this range there's no way the sensor can tell you what the position is it can tell how much signal attackin teammates but it cannot tell what the position is and that's what is called as spatial ambiguity with these kind of sensors these are especially important when we look at threads and things like that with our sensor that's not an issue the other thing with these sensors is it cannot detect surface characteristics so it the the whole web either blocks or transmits and since there is no way we can figure out if there's a feature on the web or a structure on the web there's no way this sensor technology can detect what it is the other issues that these technologies have is that image saturation issues basically what it means is that most often the receiver is saturated by light and then you have a let's say you have a small object that is there that photo cell or the pixal for that matter might be saturated and it would have some kind of a saturation issue with that so when you are trying to detect a small object or a feature there is a problem then finally the sensor resolution and depends upon the range of the sensor so if it is a single receiver element and you want to make this sensor 2 inches wide then the resolution that it can detect is going to be the same as set a solution of the A to D converter or whatever it may be so irrespective of the width of the sensor or the range of the sensor the resolution would change and that's an issue now instead of using transmittance can we use reflection of the web to measure the web position and the answer is yes we can and that's what we do with our sensor and in order to look at that let's take a look at a few concepts about basically reflection or scattering or diffuse reflection and a couple of different things that we use in our sensor technology and then our sensor is based on optical fibers and optical fiber properties or fiber optics so we'll look at a couple of concept there as well so again we have an incident light that is falling on an object and we talked about reflection transmittance and absorption actually this reflection was just like a simpler way of representation of the light the light source is going to be it's not it's not going to be like a ray it's going to be a wave in fact so what really happens is that the light falling on the object it's actually scattering everywhere and the light goes off everywhere and then there's a portion of the light that is reflected now this phenomenon where it scatters off everywhere it's called scattering or the actual technical term for that is diffuse reflection and then this ray right here which is following the typical ray optics is called specular reflection so you have specular reflection and then diffuse reflection specular reflection is usually seen in smooth surfaces polished surfaces mirrors and things like that where the light will bounce at the same angle as the incident angle and scattering and diffuse reflection is going to be seen in most materials that are not polished or smooth so almost every material that we deal with is doing the few scattering and the reason why we are able to see a color in an object on an object is because of scattering or diffuse scattering so the the reason why this is scattering in all these direction is because the surface has got irregularities on it and those irregularities have different angles and when the incident light falls on that microscopic irregularity its reflecting it back at the same angle with respect to that small microscopic surface but because we have a whole bunch of those the light is scattered in all the different direction just like scattering and reflection there's also diffuse reflection and regular sorry diffuse transmittance and regular transmittance when the light goes to it and that is not of importance for us the main thing for us is this reflection now there is another thing that is important when you're installing the sensor we talk about the angle this is mainly saying that if you have a light source that is coming at a certain angle then the maximum amount of scattering is going to happen close to the normal when we do our sensor installation there are some sense of installation recommendation that we provide that's that's mainly based on this so if you have if you want to view the object from this angle then as you can see here there's going to be a lot less light than if you view from here and likewise the light source as well this is called as Lambert's cosine law and basically you want to keep that angle as close to normal as possible so that we can get the maximum so if we use scattering how do we make a sensor that can do this again and just like a retroreflector one we have a light source and a transmitter and a receiver the the light goes through here falls on the web if the web material was perfectly reflective then all the light that goes here will exactly reflect back at the same angle which is normal to the surface and then we will have a really good image and we'll be happy but that's not what happens the light when it falls on the material it's just chaotic it's going to reflect everywhere or scatter everywhere and we're going to have the same issue like an opposing beam sensor technology where we have scattering and which will be dependent upon the material and how far the material is from the web and and the spatial ambiguity and accuracy and things like that so how do we fix that basically we add a filter to it and that's our proprietary technology so we add a filter that filters the light and the way it works is that when the light falls on the web it scatters everywhere but the filter is going to selectively couple the light coming in falling on it at a certain angle and now the light goes back now we know where the web is if this receiver is a pixel array or some kind of imaging element then we would know all these elements would receive light and all these elements would be dark and if we do an edge detection algorithm we can figure out where the web is that's the underlying principle of that and how do we create a filter that's based on fiber optics so optical fibers have special properties in that they allow the light to go in only at a certain angle like the cone that is shown here so if you have the web if you have the light falling on the fiber at an angle that is steeper than the scone it will not go in so it's basically gonna filter out all the light and allow light only coming at a certain angle to go in and that's how we do it so that's the basic fiber optic technology that we have so how does it work just to give you an illustration there's a light source that is illuminating the web and the light scatters everywhere but then the light that is directly underneath the fiber is the one that gets coupled into the fiber all the other light that is coming at an angle doesn't get coupled into the fiber and that's how we we we didn't mind what the web position is again this is a true and absolute web position measurement because the fiber has to align with the web edge for it to be able to pick up the light and just just an illustration of how we do it now essentially the light source angle can be at any angle as we saw before but we want to keep the scattering to the maximum so we're going to keep that light source as close to the receiver as possible to take advantage of the Lambert's in my inverse Lambert's cosine law so we have a light source it could be laser LED or anything like that it falls on the surface it scatters everywhere this is a side view of the optics and this is the front view of the same thing so the light falls onto the fiber optics and then the photo diode or a pixel which is position behind the fiber optics is going to pick up that light that's how we determine where the position of the web is now I mentioned that we have a pixel or a photodiode behind the fiber basically what we do is we capture the image and then we do real-time image processing to determine the edge of the material this is an important part of our sensor technology technology not just that not just the the way the sensor works but also how do we process the image is important the algorithm adapts to a few other things that we will talk about later in terms of how do you adjust for intensity changes how do you adjust for focal lengths and stuff like that so essentially a component the components of our sensor or four main components one is the light source we typically use LED light source it could be visible or a broad light spectrum or infrared or even UV light and then there is an optics that is filtering the light that is coming at all different angles that is our patented fiber-optic technology and then there is an imaging element behind that optics which is usually a linear pixel array and it's anywhere from 768 pixels to about 14,000 pixels and these pixels are arranged really close to each other at 63 and 1/2 micron or about five thousandth of an inch and then finally the image processing algorithm which actually does the edge detection so let's see how that works now we have a different samples of web that we can present to our sensor as you can see the some of them are opaque some of them are completely optically transferring some of them are porous they have voids in them and irrespective of any of those our sensor can provide a really reliable and highly accurate web position measurement I think this is a published article that you can find in converting but the but dearest the accuracy was about ninety over ninety nine point three percent with any of those materials and we didn't do any calibration that's the main thing with our sensor technology now just to give you an idea we saw the different images as you can see the light that is falling on to the imaging element is going to have varying intensity depending upon the material that we have so if we have a light scale where blue is completely dark and red is completely light or white and then there's a spectrum going through that you can see that all of these edges are are not as sharp as what we have illustrated in the working principle in spite of that this is the output of the edge detection algorithm they did the edge detection algorithm goes in and says oh this is the edge for this black nonwoven web this is the edge for the transparent web this is the edge for the load GSM nonwoven and this is the edge for the perla now we don't really just have to look at the edge of the material we can actually look at features or patterns on the material as long as the pattern is parallel to the machine direction then we can do the same thing so here for example we had some die cut edge of a label so we wanted to detect the edge right here edge right here edge right here on the edge right here so and again we can do that with our sensor technology and it provides a pretty good measurement so in terms of the the image processing feature that we have the key things there are we do what we call as dynamic threshold that means that every single image that we take every sample we do run our edge detection algorithm and it automatically to the lighting it adjust automatically to the focus it adjust automatically to the material and figure out figures out where the edges and just to give you an example again this is an image from our four 440 sensor with infrared light source black just means that there is no light coming back and then white means that it's coming back now this is the raw image on the top we presented a burlap web right there and if we just say I don't care about what's in between I just need the edge of the web tell me the left edge in the right edge then we can give an output which is going to be like this so the edge detection algorithm goes in and picks up the left edge in the right edge it doesn't care about anything in the middle now what happens if we have a lower brightness it's the same web same location we have a lower brightness as you can see these two images are pretty different with low intensity again no problem no setup no calibration the edge detection algorithm will automatically adapt to that and pick that and what happens if you have a really bad image where it's not only low brightness but it's also further away from our sensor no problem we can still do that I'm not sure if you can see this on your screen but this is really faint gradient here but we can still do that now the other things that we can also do is background suppression what it means is that we have special way of adjusting automatically so that if there is a background in the image which is at a certain distance from the web we can still adjust for it and that's what is shown here so here this is an example of a clear web with an infrared light source on it and there's some background there and we were able to automatically adjust it and provide the edge positions there now when we do this we also have additional information that we provide from our sensor we can provide an edge quality feedback that means we can say how good the edges we call it as a quality factor we can provide it for each edge that we measure and then we can also provide a flutter feedback for each edge again the quality factor is based on instantaneous measurement while a flutter is based on temporal it's a function of time so but anyway we can provide that flutter information as well now other things that we could do is one of the things with the with the conventional sensor is that it has issues with spatial ambiguity this is going to be common when you have like really small feature our sensor obviously does not have that issue and just to give you an example here is an image of a single thread this thread is like two or three millimeters wide and we can pick up a single thread like that with our sensor and and what if you have multiple threads and let's say you are running some kind of an operation where you have to guide or bring in multiple threads into your process and you want to be able to count the threads well if you present something like that we can still do that as you can see in the raw image there are some threads which are kind of out of focus or farther away some really in focus and a it doesn't matter our algorithm is able to go in and pick that up and tell you process the image and tell you the edges now when we do edge detection like this we can essentially provide you with every single edge position where they are within the sensor or most often because it's a lot of data that is going through we can actually provide you some statistics of this whole measurement so we can say well what is the average width of these threads that we picked up and what is the average gap between them so on and so forth what is the minimum what is the maximum so we can compress that in the data and provide some statistics that you can use to kind of figure it out like for example here these there are actually two threads here these two threads are really close to each other and when they are close to each other then this kind of the thread kind of became like double so if you're able to monitor that then we can figure that out and tell you that hey something is coming too close to each other or overlapping and things like that again we can with low brightness it's not an issue we can still pick up that edge right there now I talked about edges but it doesn't have to be an edge here this is basically a printed pattern that we are looking at different colors different colors are going to reflect light at different intensity again an infrared light source is illuminating a colored web here and you can see that it can pick up these contrasts so when we do contrast application what we can do is we can not only tell you the location of the edge where the the contrast is different but we can also tell you the intensity of that so that's how we can teach our sensor to follow a particular color or a line or something like that now we we have done sub-pixel edge detection so that means that we can go to one twenty thousandth of an inch or sixteen micron in terms of the resolution our standard pixels or the standard imaging element has a resolution of 63 and a half micron and we can do 1/4 or 1/8 of that to get sub pixel resolution so those are the features of our sensor in terms of the sensing principle how we do image processing and how the raw image looks like and how the process image looks like and things like that now let me just quickly go over some of the applications that we have with our sensor first and foremost we do edge detection that's one of the basic things if we want to do edge guiding then we need to do edge detection the other things that we do are with the measurement contrast position measurement contrast position detection and contrast our pattern it's pretty much the same kind of thing then we do thread counting and I showed a little bit about that we can also detect a mark on the web we can also detect a flag on the web we can also detect what we call as a coverage or the for lack of a better term optical density of the web and then finally the stack measurement so let's go over some of these really quick edge detection since our sensor is one-sided you can have a web that is coming from left to right like in this case or from right to left it doesn't matter all we just need to know is what direction we need to scan for the edge if if if the sent if if the sensor if we're looking at the right edge of the web which is this one then we're going to scan from right to left if we're looking at the left of the left edge of the web then wicker we're going to scan for from left to right now what we are going to look for is in an edge detection is the first transition from a dark to any kind of a light and that's how we would do the edge detection now I've got a short video here and hopefully it can play properly and these videos are on our website but the idea here is to show that we can put any web material and this is showing the position of the web we can pretty much put any web material and without any setup or calibration we can get the true measurement or the absolute measurement of the web this is like a highly porous non woven that we used the other extreme example is like a really porous mesh kind of a web even if we have a web like that when we do edge detection we can accurately get the leftmost edge of the web or whatever the edge that we want we can get that accurately so that's what this video is showing so some application example where we provide the most value to our customers is that whenever you are doing edge detection with frequent material change over like if you are going to detect a paper web all day every day yeah we can do that too but that's not where our value is this would be like nonwovens or any any kind of engineered material that you are changing quite frequently where you don't know the opacity and the porosity and stuff like that our sensors work great in those application or if we do width changes like I mentioned we can go from about 48 millimeters up to about 900 millimeters in sensing range without losing any resolution that means that you can run different webs without different width webs without needing to move the sensor that's another place where we have a pretty good advantage challenging materials of course that's that's our specialty is if you have something that's really complex then we can do that and then challenging environments specifically vacuum that's a place where we have got a lot of success especially when we are trying to detect clear film inside a vacuum environment now the advantages are that we don't need any setup for calibration and it's pretty cost effective in terms of connectivity we have industrial Ethernet this could be Ethernet IP or pro finet will also have EtherCAT and other things that we could do as well and some unique applications like I said clear web inside a vacuum this is pretty unique just because of the fact that most current technologies for detecting clear film or ultrasonic and ultrasonic doesn't work inside vacuum so that's pretty unique for us and then again metals that's another place where metals inside vacuum is another one since our sensor is single sided we have successfully used our sensor in abrasive environments where a web flutter or something like that they typically knock off a fork style sensor and we can position our sensor farther away from the web because our algorithm can adapt to that and we were able to do that with an abrasive web environment and then you can also do width measurement on low basis weight non-roman this is usually a problem with current sensors because they are not they're really really you need to do a lot of filtering with that or it could be some kind of an edge that is kind of ragged and we can also do like detecting ridges on a web so this could be some kind of an extruded plastic or something that has got a three-dimensional structure on it and you want to follow or see that some of those things we could do just to give you an idea the the the the sensor itself has just the optics the imaging element and the light source it doesn't have the processing so you need a sensor and a controller to do that it shows and then different output options at the hint we can have for edge sensing usually we can to analog output if you want to connect it to some legacy systems that use analog sensors otherwise we prefer to provide Ethernet IP or Pro finet for that matter option for H as output now the other common application that we do is width measurement now width measurement with two sensors or one sensor obviously this sensor is too small and if the WebWork changes then you're going to have an issue that's where we have our value where we can provide a wider sensor and what you don't have to have the sensors mounted on some kind of a linear positioners mechanical positioners these are again cost prohibitive and have inaccuracies and all those kind of things so you can avoid all of those by using a wider sensor and when the web which changes the sensor doesn't move so it can still detect the web width now if the sensor is wide enough then we can measure both edges of the web with a single sensor again this having a single sensor that does all of those then you don't have to worry about alignment the distance between the two sensors and all those kind of things this is the reason why we are moving to wider and wider sensors every year and we are about to release our 900 millimeter wide sensor this summer anyway if you have a wide sensor then you can see both edges of the web and without having any issues now most of the time these are applications in shrink sleeve so this is a one of the video from our distributor in Mexico but as you can see one of the things apart from providing accuracy and resolution in width measurement it's a safety thing so you don't really have to have somebody go in and measure a web while it's moving to make sure that it's at the site the correct width you can have an automatic automated system that can do that so here we're showing our for 40 mm sensor that is looking at both edges of the web in a shrink sleeve or a folding web application now we can do the same thing for others and some of the common applications are if you want to look at a blown film and you want to measure the width of the tube lay-flat width of the tube of the blown film a lots of different applications again this is one of our videos from our distributor in Mexico so like I said width measurement where we see it where where it's used like any time you are slitting and let's say you're slitting something that is uh that that requires you to measure the width to verify that we can use that folding the web again it could be in swing sleeve it could be other folding web applications and sometimes you can also look at the trim width just to make sure that you don't run too far out to the trim I mentioned about blown film and then extrusion like you can use it for monitoring extruded webs like resealable zippers or things like that that's where we we have our sensors installed and then you can also look at like width of tire rubber and in that case we can we actually have it in a back roller and we can do that as long as there is a contrast difference between the edge of the web and the background it doesn't have to be a clear background or a free space it can be anything then we can do that again different output options we typically prefer ethernet/ip or or or some kind of a industrial Ethernet apart from looking at the edge of the web we can look at contrasting features so basically we're taking advantage of the fact that different colors are gonna scatter light at different intensity in this case we are showing a white light a white light is typically used when we want to bring out visible contrast it doesn't have to be white light it can be UV so that you can have a fluorescence or can be IR as long as you are able to see the contrast difference and the light source is mainly used to extenuate the contrasting feature so either depending upon the frequency of the light source or sometimes the angle as well so some applications would be like if you want to look at a coated edge and you want to see how far the coating is to the edge lithium ion battery or any kind of coating that you can do even just regular paper coating you can do that and in paper coating case you would probably use a UV light so that most often that coating on the paper has some UV fluorescence to it or it can also be like looking at maybe tabs or things like that on a conveyor we can do that too and then not only are we detecting the contrast we can also provide the position of the contrast so you can use it for control purposes as well I've got a couple of videos here but I'm gonna skip that and you might be able to see that in our in our website I think I talked about this quickly so anytime you are guiding in a slitter where you want to slit to a printed line that's an application that could be in a doctor machine as well if you want to follow a UV line then cording width measurement and then some other simple inspection applications here's a quick video where we have a application where our sensor is installed to look at this bag which has an extrusion which is clear and then the bag itself is opaque the the idea is to measure the width of the green part of it and disregard the clear part of it and we are able to do that in this case it was installed with the free space at the back but it doesn't have to be free space you can actually install it with the back roller on it here we have an example of our sensor used to detect the width of the web where the web is supported on a roller and there is a contrast difference between the roller and the web and it's it's not clear here but we use a white light source in this one and we're actually looking for the edge of the clear film and not the edge of the printing and with the light source and we can do that and this is made this one is for width measurement for detecting wrinkles so whenever you have a wrinkle on the web that's going to reduce the width wrinkle or a fold over that's going to reduce the width and we can use our sensors to measure that there or like I said in the other application would be like if you have a tire width measurement application you have two sensors that are mounted and it can look at that the tire and in this case they they were kind of a little bit creative about it and they put a background that is white and then the tire by itself is black and the reason why it's black it's because it's absorbing all the light so in order for us to detect this we need to have a white background and then and then a clear a black foreground which is our web then we were able to detect that so that's our common width measurement application I briefly went over this this is another thing that we do is like string thread fiber monitoring so it could be like things that you use in textile and waist bands or or carbon fiber applications where you want to accurately measure multiple webs and in this case we would be able to do measure and count and provide statistics on what is the minimum what is the maximum what is the gap so on and so forth and we can also provide additional information like that again I'm going to skip this video for the sake of time and like I mentioned it's elastic thread or textile or carbon fiber any of those the main advantage here is that we're replacing some camera based system with our sensor and then for thread detection we are replacing mechanical pulleys and and pressure-sensitive sensors and we can actually stitch together multiple sensors over Ethernet our 440 sensors we have installed it up to 2 meters wide where we have connected four of them together which is possible the next application is marked detection so again we're trying to look for a contrasting mark which is a which is going to have different scattering and we can do that the main difference here is that the mark is along the machine direction sorry if it's it goes faster it's not a consistent mark that comes and as in a printed pattern or things like that but it doesn't matter we can still detect that and it can be a visible mark or UV fluorescent mark any of those and it's not only that we can detect the mark we can actually track the mark in terms of position that means that we're not just saying giving you an on-off signal we can also provide an analog output that tells you where the mark is with respect to the sensor the main advantage there is that we have a wider sensor so if the web moves we can still track the mark we can also detect flags on the web so let's say you have a web and it's got multiple flags you are going into a slitter now you're going to remove all the flags and then you're going to another process and then you want to put the flag back in how do you do that then you can detect a flag and then have some kind of a thing that would put the flag back in again after you complete it this is a little bit even though that you can see that the flags are different colors different weights different sizes the web may be different we can do all of those without any need for teaching I can adapt to different flags and different webs and it is not affected by web wander or web moving back and forth then we can also provide a quality signal in that case we can also do tear detection or coverage this is just an illustration or example of let's say there is a tear in the web and then the web actually splits we can detect that this is an exaggeration but if the tear is small we can still do that now if the web separates and moves the left and the right edge moves then that's an easier one to detect but if the web's doesn't move and you just need to see a wide or a hole again we can detect that again all of this is based on how much light we are getting when there's nothing when there's a wide or a hole or a tear if this region is going to be dark and this region is going to be white and then we can basically integrate how many pixels that are white and how many pixels that are black and that gives us the coverage and by monitoring the coverage you can detect if there's a hole or tear or anything like that one other application that we do is we could do is also product linked measurement basically what we do here is we just rotate the sensor 90 degrees and when the product is moving on a conveyor it can track the edge and it can basically say how wide the product is the main thing with this is that the sensor doesn't have to be longer than the product and then the product can run at different speeds and you don't need an external synchronization signal to be able to pick up that so that's a quick summary of some of the applications that we have just to summarize the advantage of our sensor technology is that it's accurate it's got it provides an absolute measurement it's very simple to use when you compare to like a traditional fork style sensor or maybe even a camera based sensor the resolution is not affected by range in a camera based sensor if you want to have a bigger range you have to install the camera at a certain working distance and when you do that you lose the resolution we don't have to worry about that in our case and it's a one-sided sensor so like in a camera based system you would have to install the camera or the light source the gantry all of those here it's all enclosed fully contained and because the sensor is going to be close to the web we can have a pretty good lighting control and then it's also compact in terms of installation and we have done a lot of customizations for our sensor and these would include processing speeds of up to about thousand Hertz and then we can track multiple edges there's really no limit to the number of edges we can track it's just that the information how do we send it and then sub-pixel approximations I mention that before two to eight X we can do that and we can also control the edge detection through Ethernet industrial Ethernet and then light source customization based on the application and then essentially the customisation is bringing us more and more close to a line scan camera based system but at a much lower cost and the difference is that we actually do the customization and we don't just sell the the the sensor and the imaging we actually do the processing as well unlike other line scan based systems so that's essentially my presentation and here is the contact info if you have any questions or any application or any need for sensors please let us know and I do have some questions in the Q&A section so let me just quickly go over some of those and see can your sensor technology by the way please use the Q&A section to ask any questions if you have can your sensor technology also measure a webs thickness across a sheet of material while in motion if if that's true what when a number of threads are being read in addition to placement of threads in their respective spacing can you also read the thickness yeah the the thickness we can't do that right now not in the current state we can look at what we are doing is we are taking a projection of the image a actually it's a 1d projection of the image and since thickness is going to be in the other dimension there's not a way for us to detect both at the same time so we cannot do that what types of industrial Ethernet do you utilize yeah we can use Ethernet IP Pro finet and we can also do either cat and then other other things other protocols okay what is the minimum distance between slit webs that would allow the sensor to measure the slit width of multiple webs parallel to each other okay that's a great question so if the if the if the web can scatter a lot of light then I would say we could do probably one or two millimeters and we can easily have one or two millimeter gap between the web's and be able to detect the slip web width that's something that we could do and then what is the working distance so the working distance for the sensor is really depend upon the the amount of light that is being scattered our normal working distance that we specify is about 10 millimeters it's pretty close to the web and by putting the sensor so close to the web we have a pretty good control of the lighting and that way we can we can have a pretty good image now there are applications where we have installed it more than two inches or maybe even three inches from the web surface so it really depends upon the amount of scattering but for anything that we want to do like width measurement and things like that we would we would want that distance to be within our specification so that we can provide a pretty accurate measurement and then the other thing that I forgot to mention about the width measurement is that you can measure the width in a free span or a free space but as we showed if you measure the web width on a roller if you can get the contrast difference and you can measure on a roller then that provides the most accurate measurement because you don't have to worry about focusing and things like that even though our algorithm can compensate for it but it's it's better if we can have the web stabilized let's see um gee so that's probably all the questions that I have I hope you have a had a chance to fill out our polls that be organized and if you haven't done that you can use the tab on the left to be able to see the polls and that would be really helpful for us so that we have a better understanding about what your needs are and how we can help again my name is are Arvind Seshadri and we really appreciate your time today to join us during our webinar if you go onto our website you should you should be able to see most of the stuff that I talked about today in terms of videos they should be on our website and then if you have an application and you would like to talk to us please give us a call or contact one of our distributors or sales reps in your respective region and they would be able to help you with any of your needs if there are no other questions then I will conclude this webinar once again thank you so much for your time

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# SCU5 Controller

URL: https://r2r.tech/videos/scu5-controller.md

Roll-2-Roll Technologies brings you the latest in web guiding technologies. We are now offering you SCU5 controller, so you can use our sensors in any kind of environments. 

## Transcript

This is Pedro Velasco from Roll-2-Roll Technologies and today we're a test bench where we you know do some variants of our products. I want to talk to you today about one of our products that we have on the sensor control unit side. Now one of our options for smart sensor control in our line of products is the ARIS SCU for control cabinet mounting on a thin rail as we have shown here. Now we have arranged the sensor control along with a couple sensors so we have two units with two sensors that actually for burning.

This was originally designed for OEMs who wanted to as an in capita control unit and they wanted to use our sensor technology with their own actuator systems and their web guiding systems. Therefore they were benefiting from our technology from our smart technology that's offered in our whole line of products now. The ARIS SCU provides it can provide an analog output, a connection for Ethernet IP applications, an operator interface so to connect the display to it and then on the bottom side, you can see we'll have the two sensor controls, two sets of connections now. The sensors then, the sensors we provide with this, would be with a shielded cable and they can be installed far away.

This is particularly useful for those applications where the sensor needs to be in an environment in which the control unit cannot be in. For say for example, an environment like a vacuum environment now the ARIS SCU can also be used in other applications. You know like for the detection of web positions, monitoring measurement of web width, any industrial operation so it's not only for those OEMs it can also be used for those who have a very special applications like I mentioned before. Applications where the environment wants or requires that the sensor control unit be away from the sensor.

Now this is a lightweight, easy to install, smart sensor control unit that is a coupled with our sensor technology and it allows you to detect and monitor any material position without the need for calibration. For more information subscribe to our YouTube channel and check out other videos that we have with additional tips and tutorials on our products. Thank you.

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# SCU5 Web Width Measurement Setting - One and two sensor application

URL: https://r2r.tech/videos/scu5-web-width-measurement-setting-one-and-two-sensor-application.md

The tutorial demonstrates the procedures to setup the SCU5 Roll-2-Roll® Controller for web width measurement with one sensor and two sensors. It is a step by step presentation of navigating through the controller screens to set the controller and sensors for width measurement applications. The video is part of the support documentation for the [SCU5 manual](https://r2r.tech/sites/default/files/2020-03/SCU5_%20Sensor%20and%20Web%20Guide%20Controller%20User%20Manual%20v3.4_0.pdf)

## Transcript

the su-5 controller can be set for with measurement for one sensor and two sensor applications for this demonstration we have set an su-5 controller shown in the main screen and a wps 112 sensor and a wps48 sensor which are both shown on the smaller screen screen on the upper left hand side to set the su-5 controller for width measurement with one sensor you need to follow these steps make sure the sensor selected has a sensing range wider than the material you are measuring verify that the sensor is connected to the sensor port you will be using for this demonstration we have selected the wps112 to be the sensor on sensor port one this sensor port is on the upper right hand side of the controller the wps48 which we were using in the two sensor application is set on sensor port two which is on the lower right hand side of the controller on the operator interface screen you will see that the controller is set to guide point offset we will change the setting later to width measurement we press the tool icon to access the advanced settings screen on the advanced settings screen we press the operator setting icon to access operator settings screen on this screen we press the sensor icon in the sensor screen we make sure that sensor 1 is selected when the icon is pressed it will toggle between sensor 1 and sensor 2. make sure that sensor 1 is selected next to it is the icon for threshold this should be in dynamic mode which is shown in green if the icon is red with a flat horizontal line it is in static mode make sure that for this application it is on dynamic mode the last icon is the sensor mode when the icon is black and white it is in edge mode when it is black green and white it is in contrast mode for this application the sensor mode should be in edge mode return to the advanced screen and we press power user icon which is on the lower right hand side on the power user screen we press sensor icon and then we verify that the sensor in use for the application is enabled in this case it's sensor 1. sensor 2 should be enabled because we're doing a one sensor with measurement application we verify that the sensor one is on center mode and that brightness is an automatic we press return to the previous screen and we press the analog output make sure that the analog mode is in with and that the analog setup is normal we return to the advanced settings screen and then we press the power user icon we press the width icon we press the teaching one and then we accept this will set the value to zero when the material is presented the screen shows the actual width of the material the output type icon indicates what type of output you will be seeing on the operator interface screen when it is set to absolute the operator interface screen will show the actual measurement of the material the width when it is set to error the measurement shown on the operator interface screen will be the difference between the actual measurement and the nominal width that we have set on the width screen to set the nominal with we go back to the sensor and then we select nominal width the nominal width can then be changed by using the adjust icons on the bottom of the screen this can be adjusted for increase or decrease of the value by 0.25 1 10 or 100 millimeters when you press one of these buttons it will turn green and the nominal width can be adjusted positively or negatively by that value through the arrow icons upper and lower limits can be adjusted in the same manner as we return to the previous keep screen by pressing the return screen button we can go back to the main operator interface the output will be shown in millimeters and in this case it's still showing the error if we want to go back we can change it to absolute one thing to verify is we should have noticed that the controller is now on web width mode as shown here this controller is now set to measure the width of material with one sensor for a two sensor application the sensors should be installed in that appropriate orientation one sensor should see the left edge and the other sensor should see the right edge for most applications the sensors should be in edge mode if the two sensors are exactly butted together against each other then the sum some of the two sensors would be the web width the measurement from each sensor is the amount of web seen by each sensor which is the raw width if the two sensors were overlapping or they would have a gap between them the offset then is either negative or positive hence the measured width would be the sum of the web covered by each sensor plus or minus the offset in order to record the correct offset offset the user should present a web of known width preferably that is known equal to the nominal width at the desired working distance from the sensors ensuring that both edges of the web are seen by the sensor if that known width is different from a nominal width then the value can be entered as the nominal width before pressing the teaching one in this case we know that this material is 100 139 inches wide so we go to the width measurement application and we set the nominal width at one hundred thirty nine and we present the material press the teaching icon and we have set the sensors for the two sensor application you

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# SCU6x Controller   Center Guiding with Two Sensors

URL: https://r2r.tech/videos/scu6x-controller-center-guiding-two-sensors.md

In this episode, we discuss situations where using two sensors becomes essential, particularly when the sensor is not wide enough for the web being monitored. The video demonstrates configuring two sensors: sensor 2 for the left edge and sensor 1 for the right edge. When a piece of paper is presented, it is partly seen by both sensors, allowing them to determine its position. The green line indicates the center line position, while the left and right edges indicate the web's boundaries, showcasing the capabilities of the SCU6x Controller.

00:00 Introduction to Sensor Configuration
00:22 Configuring Left and Right Edge Sensors
00:29 Demonstrating Sensor Coverage
00:39 Interpreting Sensor Data

## Transcript

so there are situations where we would have to use two sensors and uh if the sensor is not wi enough or the web is much wider than our sensors then um we would have that scenario I have this sensor tool which is this sensor I have that configured for left Edge in sensor one I have that configured for right Ed and then now the i% a paper that is partly seen by One sensor and partly seen by the other sensor then we're going to see that and then again the green line indicates the center line position and then the right edges and light of the left edges indicate the edges of the w

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# SCU6x Controller   Firmware Version

URL: https://r2r.tech/videos/scu6x-controller-firmware-version.md

This video will discuss the firmware number on your SCU6x controller. You'll learn how to find the firmware number and how it is crucial for troubleshooting and understanding the capabilities of your controller.

## Transcript

[Music] the next thing that we focus on is going to be this top right hand corner it says B2 4.2a it's kind of hard to see for you but believe me there is a firmware number there so that is basically the firmware number or the firmware version number for this particular controller this is another common thing that we would ask especially for troubleshooting purposes what that firmer number is and if that doesn't give us enough information we do also have another firmer number on the back which is printed on our product label and that is for if we want to get deep down into it so when do we change these firmer numbers on the top here uh anytime there is a significant change where we are doing a bu fixing we would change that fare number and also anytime there's some UI changes so anything with related to the buttons adding a new screen or removing a a different screen we would change that firmer number so in general we don't remove any features we only add features to our system so most often if you have a product manual that says version 4.2a most likely it will be applicable to a version 4.1 or 4.0 as well another note if you're familiar with our seu 6X controllers or if you are familiar with roll to- roll Technologies we haded se5 controller before and now we have the se6 the SCU 6 all start with version 4. something and seu 5 all start with version 3. something that is the firm number

---

# SCU6x Controller   Functionality of Sensor Orientation Buttons

URL: https://r2r.tech/videos/scu6x-controller-functionality-sensor-orientation-buttons.md

This video demonstrates the sensor orientation button functionality on the SCU6x controller for web guiding and monitoring applications in the converting industry. Learn how this feature allows you to quickly switch between two sensors installed in opposite directions, depending on whether the web is moving forward (unwind) or backward (rewind).  This eliminates the need to navigate multiple screens, saving time and improving efficiency. Ideal for machines where the web can move in both directions, such as unwind and rewind applications, the SCU6x controller simplifies sensor management and ensures accurate web guiding regardless of web direction.

## Transcript

there are also applications where we have one actuator guiding the web and there might be a scenario where we want to guide the web with one sensor in One Direction and the other sensor in another Direction these are commonly seen in machines where the web can go both in forward and reverse Direction especially in an unwind or a rewind you can have it configured where in One Direction the the system behaves like an unwind with a sensor installed on the fixed machine frame and then when it goes in the backward Direction the same system behaves like a rewind where the other sensor would be installed in a chasing kind of configuration in those cases we can switch between the two sensors pretty quickly just from the home screen without us having to navigate to multiple screens to enable or disable the sensor so that's the functionality for the sensor orientation buttons

---

# SCU6x Controller   Heartbeat Indicator

URL: https://r2r.tech/videos/scu6x-controller-heartbeat-indicator.md

Heartbeat LED Indicator in the SCU6x Controller: Your Troubleshooting Companion This video dives into the critical Heartbeat LED indicator found in the SCU6x controller. Learn how this small light plays a major role in monitoring the health of your system and aiding in troubleshooting. We'll explore: Heartbeat LED Location: Find the Heartbeat LED on your SCU6x controller. Blinking Pattern and Meaning: Understand what the blinking red and green (or green and no light) pattern signifies. Communication Status: Discover how the Heartbeat LED reflects the communication between the motherboard and the operator interface. Troubleshooting Aid: See how the absence of the Heartbeat LED's blinking can pinpoint issues with the touchscreen or communication. Don't overlook this simple yet essential indicator! The Heartbeat LED is your first line of defense when troubleshooting your SCU6x controller.

## Transcript

[Music] first and foremost thing that I want to point out is what we call as the heartbeat LED this is basically the bottom left hand corner and this particular LED is blinking between red and green in the seu 6X there's actually another led a physical LED that's available on the side which is label B zero and that will also blink between green and no no light so we call it a heartbeat which means that this is very critical and we want to make sure that this led is blinking all the time so this is again one of those things which is used for troubleshooting purposes if you call us and say hey something is happening nothing is working when we touch the um operator interface the first thing that we're going to ask is that hey is this heartbeat LED blinking and what it is indicating is that there is the program the motherboard is running and the motherboard is communicating back to the operator interface and and the motherboard if there is no communication between the display and the motherboard then this led would stop blinking so that's a good good indication to say that there's something wrong with just the touchscreen operator interface the motherboard is still working fine

---

# SCU6x Controller   Sensor Setting Demonstration

URL: https://r2r.tech/videos/scu6x-controller-sensor-setting-demonstration.md

Understanding Web Position Monitoring with the SCU6x Controller In this episode, we showcase the functionality of the SCU6x Controller's web position monitoring system. By focusing on the left edge of the web, we demonstrate how the white region in the web position indicator represents the web, while the black region indicates the background. As the web position moves from right to left, the indicator updates accordingly. We also explore how changing the orientation to the right causes the bar to switch directions, allowing for precise monitoring of web positions.

 00:00 Introduction to Web Presentation

 00:05 Understanding the Web Position Indicator

00:30 Configuring Web Orientation

## Transcript

so I will present the web right now and we're looking at the left edge of the web and as you can see that the white region in the web position indicator is representing the web and the black region is representing the uh backround or M so as I move back and forth if I have the Lage configured for the orientation then as I move from right to left the web position is going to increase from right to left just like what you see on the screen if we change that orientation to right the bar automatically switches and it goes in the other direction just like what be right

---

# SCU6x Controller   Web Detect Indicator

URL: https://r2r.tech/videos/scu6x-controller-web-detect-indicator.md

This video focuses on the Web Detect Indicator on the SCU6x controller interface. Learn how the Web Detect Indicator functions, what it looks like under normal operating conditions, and what to do if it's not functioning properly. The Web Detect Indicator should be green when the web is present and gray when it's not. If the indicator is blinking, it could indicate a problem with the sensor, such as improper installation or angling.

## Transcript

[Music] another key thing on the bottom left right about that heartbeat LED is called a web detect indicator right now you can't see anything it's gray but when I present the web there it turns green when I take it off it's gray so that is what we call as a web detect indicator think when when you are under normal operating conditions that uh should be green all the time I'm going to make it kind of flicker back and forth just by moving the web closer or farther away from that sensor and you don't want that to be blinking like this that's not a good sign and then the first thing that we are going to look at is is the sensor installed properly is there something in the background on the sensor that we need to consider and and is it angled properly so that it's not picking up something and losing the web position both heartbeat and web detect indicator are two important things that are available on the home screen

---

# SCU6x Controller   Web Position Bar

URL: https://r2r.tech/videos/scu6x-controller-web-position-bar.md

Understanding the Web Position Indicator on the SCU6x Controller In this episode, we dive into the functionality of the web position indicator on the SCU6x Controller. This segment focuses on explaining how the indicator bar works to show the web's position, which changes based on the sensor connected and other parameters. Join us to learn how to effectively monitor and manage web positioning using the SCU6x Controller. 00:00 Introduction to Web Position Indicator

## Transcript

the next thing we want to focus on is this bar right there which is called as the web position indicator and uh depending upon what sensor we have connected that bar will show the position of the wed and so for example if I put the web there you can see that it's showing that position and the way the web moves depends upon other parameters but that's indicating the web position

---

# SCU6x Controller Actuator Bar Screen

URL: https://r2r.tech/videos/scu6x-controller-actuator-bar-screen.md

In this episode, we delve into the details of the SCU6x Controller's features, specifically the actuator position bar and the servo center button. By pressing the motor icon on the home screen, users can get a larger view of the actuator position, allowing them to observe the movement of the web guide. The video highlights the importance of understanding the distinct functionality of the servo center button compared to its role on the home screen. Viewers are encouraged to watch subsequent videos to fully grasp these features before using them.

00:00 Introduction to Actuator Position Bar
00:07 Exploring the Motor Icon Functionality
00:24 Understanding the Servo Center Button
00:34 Recommendation for Further Learning

## Transcript

one other thing that we have is basically this actuator position bar if you press that motor icon on the hle this let you see a bigger view of the aurator position K in this case if the web tag moves back and forth you can see that actuator bar will move back and forth one thing to note about this Servo center button is that this has a different functionality than what it is in the home screen so we recommend that you take a look at the subsequent videos about this functionality before using this

---

# SCU6x Controller Actuator Position Bar

URL: https://r2r.tech/videos/scu6x-controller-actuator-position-bar.md

In this episode, we delve into the functionalities available on the home screen of the SCU6x Controller. The video also explores the actuator position bar, explaining how it indicates the position and status of the actuator, including visual cues when nearing stroke limits. We also touch upon the electronic limits set within the controller and how they influence actuator movements.

00:00 Introduction to Home Screen Functions
00:20 Understanding the Actuator Position Bar
00:46 Visual Indicators of Actuator Position
01:13 Electronic Limits and Stroke of the Actuator
01:28 Jogging Commands and Limits

## Transcript

everything that the operator need should do on a day-to-day basis can be done from the home screen for example things like putting the web guide in automatic or manual jogging the web guide back and forth and then putting the web guide in the symol center mode the first and foremost thing with with regard to the actuator is this actuator position bar this bar is going to indicate the position of the actuator and this position is the electronic position that is being read by our driver right now the actuator is in the middle as we jog the web guide you should see that actuator position to be changing and then there's also visual indication of when the actuator is getting near to its extreme position and that's indicated by this um yellow and then if you keep moving it turns red which means that there's really not much left in the actuator position so this is indicating that it's reaching its stroke Lane now in terms of the stroke of the actuator these are all electronic limits that we have in the controller in subsequent videos we will talk about how one can change those limits based on what the actual actu stroke T takes like that so this is the J if I press this one you should be able to see that go J left and it'll do the same thing if it goes to a certain position where it's getting closer to its extreme it's going to be yellow they keep going let SC the get red and then if it's off the screen even if the actuator presses this button um nothing happens and that's because the actuator is reached this limit there so it will not move in that direction however it will move in the other direction so that's the actuated position more then we saw the jog left and J right command there

---

# SCU6x Controller Automatic Web Guiding

URL: https://r2r.tech/videos/scu6x-controller-automatic-web-guiding.md

In this episode, we delve into the functionalities of the SCU6x Controller, focusing on the manual movement of the actuator to aid in the loading and unloading of the roll. The highlight of the video is the automatic web guiding system, which ensures the web is steered to its correct position. The presenter demonstrates how the actuator responds to the positioning relative to the guide point and explains the actuator's movements and limitations based on error correction. The video showcases the capabilities of the SCU6x Controller in managing web alignment automatically.

00:00 Introduction to Manual Actuator Movement
00:12 Automatic Web Guiding System Overview
00:20 Demonstration of Web Guide in Action
00:32 Understanding the Guide Point and Actuator Movement
00:53 Actuator Position and Error Handling
01:14 Automatic Feature and Edge Guiding

## Transcript

okay this is about moving the actuator manually to facilitate loading and unloading the r but the real thing with our system is basically it does guide the web automatically to its desired position so just to show you that let me present the web put the web guide in automatic mode so as you remember that the gray bar in the middle is basically our G point and if we are on one side of the G point the actuators will move one way if we are the other side of the G point the actuators for to M be away and it's that's out it's stting the we and then the actuator position bar indicates what the stroke of the actuator is and obviously once a r it stroke it doesn't matter how much eror we have the accelator is not going to move in that direction but if the eror is f on that direction then the aurator is for Mo and you that in for BL so this is the automatic feature of our web guing system and right now I'm using a single edge to gu the material and it doesn't matter if I have one Edge or two edges it will do the same thing

---

# SCU6x Controller Center Guiding One Sensor

URL: https://r2r.tech/videos/scu6x-controller-center-guiding-one-sensor.md

Understanding Sensor Orientation and Edge Guiding with the SCU6x Controller

In this episode, we dive into the functionality of the SCU6x Controller with a focus on sensor orientation and edge guiding. You'll learn how to enable a sensor in center orientation mode, which allows it to detect both edges of the web. The green line in the middle signifies the sensor's center position, crucial for center guiding. We also explore how switching to left or right modes adjusts the reference edge used for guiding, highlighting the controller's automatic detection and response to these settings. Understanding these configurations will help you effectively manage web positioning and improve operational efficiency.

00:00 Introduction to Sensor Configuration
00:16 Understanding the Center Orientation
00:48 Center Guiding Explained
01:02 Controller Modes and Edge Detection
01:29 Practical Examples of Edge Detection
02:12 Configuring Orientation for Guiding

## Transcript

I'm going to disable it and enable this sensor but I'm going to do a center orientation for that this means that we have a a sensor that is wide enough that it can see both edges of the we the first thing that you're going to notice is that there is a green line in the middle and that line is indicating the center position um off that sensor and when we present the web here then you're going to see both edges so that means that the left side is dark the right side is dark the middle region which represents the web is going to be white and then the green line is the center line of the we and that's what it's showing there it's being mov from left door so when we do Center guiding the reference or the edge position for that guiding is indicated by this green line right there so in this case in Center the controller automatically knows that if you set it in Center mode then it needs to look at the middle position of the WB and if we put it back to left mode it's going to look at the left Edge and the green line is still there and it's kind of hard to see but it's at the leftmost point of the white region and that's what we call as um The Edge position so this is what is used for control now you rest respect to of what we have it doesn't change my Edge position and also notice that I only have one edge of the web or I have both edges of the web break here but it's only looking at the left Edge so when I have this uh small piece of paper where I see both edges if it is configured for the left Edge it will only pick up the left Edge and if I do Center you can see both edges and if I do right it'll only pick up the rage and that's how it works so it doesn't matter if the web is wide enough or wider than the sensor field of you how we configure the orientation will dictate what Edge the is used for guiding or uh control purposes

---

# SCU6x Controller Center Guiding with One Sensor

URL: https://r2r.tech/videos/scu6x-controller-center-guiding-one-sensor-0.md

In this video, we explore the process of center guiding using a single sensor. Unlike edge guiding, which focuses on one edge, center guiding utilizes both edges, making it highly effective for managing changes in web width. The tutorial covers setting up the sensor to detect the web's voltage, aligning the web's centerline with a guide point offset, and maintaining the center position with the actuator. The video also highlights the advantage of this method in handling width variations seamlessly and ensuring consistent alignment to the centerline, even with variabilities. Additionally, it addresses how the sensor deals with web breaks and resumes operation efficiently.

00:00 Introduction to Center Guiding
00:15 Setting Up the Sensor Orientation
01:00 Advantages of Center Guiding
01:29 Handling Width Variations
01:57 Center Guiding Mechanism
02:18 Edge Guiding vs Center Guiding
02:24 Web Break and Guide Point Reference
02:52 Conclusion

## Transcript

so the next thing that we're going to look at is we showed how to do Edge guiding with a sensor now we're going to do how to do Center guiding with the sensor so I'm going to change this orientation sensor orientation so that sensor one can detect voltages of the web and that's what it it's detecting and as you remember from our previous video when we do Center gu and the GU the reference for the web is not based on one Edge actually based on the two edges so that's what is presented by this green bar so if I move the center line of that web to this green bar to this point box act and then put it an auto then when that Center Line changes position that's how we're going to guide it essentially s guide so what is the advantage of Center guiding is that when you hand weight changes you don't have to move the sensor as long as you get Point offside is the right location so for example if I put another web that's wider you can do a on the Fly Wick change with one to another web Wick and it will automatically guide and either one in a SLE L position and that's one of the biggest Advantage with a center diting solution is that when the wit changes let's say it have some variability in your Bri your web will always be presented to the center line of the machine as long as the center as long as the sensor is set up properly then you can bring it to that Center Line position with respect of the quadr or half an inch we with so in terms of Center guiding Center position is represented by the green bar and then the web guide is going to keep that Center position um I'm moving the actuator back and forth so that green bar aligns with that gray gray T point and preference as it should so that's the main difference between Edge guiding and Center Tiding again you still have that option of web break so the web braks it will stop actuating and it will start back actuating when the web is stressing and then obviously it's going to do it it's going to stop until the web reaches its B Point reference if the WID ches doesn't matter that's long red W the center line set so that's Center D with with a single sensor

---

# SCU6x Controller Confirming the Guide Point Adjustment

URL: https://r2r.tech/videos/scu6x-controller-confirming-guide-point-adjustment.md

In this episode, we explore the safety features of the SCU6x Controller regarding guide point adjustments. The video highlights measures taken to prevent accidental changes and ensure that adjustments are made intentionally. Critical steps include limiting how far the guide point can be moved and implementing a reset mechanism that reverts to the original settings if changes are not accepted. Learn how these precautions help maintain proper setup and visibility of the web for optimal performance.

00:00 Introduction to Guide Point Restrictions
00:05 Safety Measures for Guide Point Adjustments
00:19 Accidental Changes and Reset Mechanism
00:59 Ensuring Intentional Adjustments
01:10 Final Setup and Web Visibility

## Transcript

and then we don't allow you to change the guide point all the way to one side like that so if we do that it will go only to about a certain amount and that's just for safety purposes and then just to be sure that somebody doesn't intend to do something what we also do is that if somebody press this button and let's say that it it shows the reset gate point to a new gate point and if you didn't intend to do it all you have to do is just leave it alone for a little bit and then that will automatically reset unless you press accept any change to this accidental change it will show that the the current or intended gate point is minus 16.7 but if you don't accept it it will go back to its original G Point reference whatever you had it before so just to avoid any accidental changing uh we do that and it's the same thing with this reset gr point if you press that button unless you press the accept anything that we do here is not going to change the G white unless somebody intentionally says that that's what they want to do we want to make sure that we have everything set up uh properly where we're able to see the web

---

# SCU6x Controller Electronic Stroke Limit for Actuators

URL: https://r2r.tech/videos/scu6x-controller-electronic-stroke-limit-actuators.md

## A Common Customer Concern, Controlling the Actuator when the Web Breaks

In this video, we address a common customer concern about actuators in the event of a web break, focusing on the safety features of the SCU6x Controller. We cover how the actuator will not drive to a mechanical limit due to electronic limits, preventing burnout. Additionally, we discuss the advanced digital system of our stepper motor-based actuators, which includes electronic stroke limits, limit switch options using NPN proximity sensors, and the lock on lost edge feature. These features enhance safety and longevity of the actuators, ensuring reliable performance.

 00:00 Introduction to Actuator Safety Concerns

00:39 Electronic Limits and Safety Features

01:28 Limit Switches and Proximity Sensors

02:03 Hardware Implementation of Limit Switches

02:50 Comprehensive Safety Options

03:09 Conclusion and Benefits

## Transcript

One of the common questions that we get asked from our customers is about our actuator in the sense that if the web breaks will the actuator keep driving to one direction or not. We saw that feature before where if we enable that lock on lost edge when the web breaks the actuator doesn't move and stays put. Now in the scenario where you don't have that enabled will that drive the actuator to its mechanical limit? The answer is no.

We have electronic limits set on the actuator. That means that even if there is no web, the actuator is only going to go to its electronic limit and it's not going to go any further than that and it's going to stop there. So there is no issue with the actuator burning out or anything like that and hitting the mechanical limit. These are artifacts of older web guides which does not have that intelligence.

Ours is all digital stepper motorbased system and we have a lot of options where we are able to have complete control over the actuator position and we can set those electronic limits to avoid the actuator hitting any mechanical limits. For those customers who want a little bit more safety conscious thing where they want to have limit switches, we do have that option. So this controller SC SU6X controller allows you to connect two limit switches apart from the servo center proximity sensor. And these limit switches, even though we call it switches, they're not mechanical switches.

These could be any NPN proximity sensors that just looks at a flag that's going to tell what the limit is. So you have a left limit switch and a right limit switch. When we have that enabled, if the actuator is going in the left direction and hits the left limit switch, it will not move anymore. This limit switch would be a proximity sensor.

As soon as that flag is seen by the proximity sensor, in that left direction, it will not move. It will still move in the right direction, but not in the left direction. This is an hardware implementation. So there's no software involved in this.

Even if our system has some things that we have set up, it'll be an hardware limit there. Likewise, you have a right limit switch, which is an NPN proximity sensor. When the actuator moves and brings a flag in front of the right limit switch, the actuator will stop automatically. So, it's more like a belt and suspender and suspender approach.

So, you have three different options. One is the actual stroke limit on the actuator electronically and then you have these limit switches and obviously you have the lock on lost edge. All of these things is going to allow you to be able to have a longer life for the actuator and this is again with the advances that we have with our controller. We have a lot of flexibility in controlling the actuator and increase its life.

---

# SCU6x Controller Fine Guide Point Adjustment

URL: https://r2r.tech/videos/scu6x-controller-fine-guide-point-adjustment.md

In this video, we delve into the intricacies of making fine guide point adjustments in web guiding systems, particularly during processes like lamination. Traditional methods use a micrometer screw for adjustments, but this video explains how to make precise, real-time guide point changes automatically. Learn how to adjust the guide point by increments of 0.1 millimeters, ensuring optimal alignment without stopping the web movement.

00:00 Introduction to Fine Guide Point Adjustment
00:47 Understanding the Guide Point Offset
01:14 Executing Fine Adjustments
01:34 Automatic Mode Adjustments

## Transcript

now there are situations where you are guiding the web you got it at the part but you want to make a fine adjustment and with the traditional sensors there might be something like a micrometer and an operator needs to reach in and try to adjust that screw on the micrometer to move it back and forth to do what is called as a fine day point adjustment so think of it like a lamination process you got the wind allign guiding but you want to change that gide point just a little bit you don't want to make too much of an adjustment and you want to do that while the wind is running and that is what we call as a fine G point adjustment how to do the fine gate point adjustment right now the gate Point offset isus 119 mm and if I want to change that just a little bit then I if I want to increase that I can press that increases that the web gate is not going to move until it goes away from B so just to illustrate the SP thing now it reach the limit for the dead man and it's continuing there that's our fing G point adjustment so this allows you to be able to Mike uh make very fine adjustments to the guide point again the plus arrow allows you to increase that g point and minus Arrow allows you you would decrease that g Point that's what is called a fine G point adjustment and this adjustment can be done only when we are in automatic mode and then each press of that will take1 mm I think that's what it looks like1 mimet to move the gate BL

---

# SCU6x Controller for Different Guiding Applications Based on Actuator Thrust

URL: https://r2r.tech/videos/scu6x-controller-different-guiding-applications-based-actuator-thrust.md

In this video, we dive into the SCU 6X controller and its capabilities. We discuss both the SCU 6X MD and SCU 6X MXD models, focusing on their use with low and high thrust actuators. You'll learn about the specifications, including current draw and thrust force, as well as the different connector and power input requirements for each model. Perfect for anyone involved in web guiding technology.

00:00 Introduction to SCU 6X Controller
00:17 SCU 6X MD and MXD Options
00:30 Low Thrust Actuator Details
00:58 High Thrust Actuator Specifications
01:25 Connector and Power Input Variations

## Transcript

so what we have today is our SCU 6X controller this is SCU 6X MD and we have one sensor connected to it then in the motor port we have an actuator connected to it right there seu 6X MD and there is another option SCU 6X mxd both of these options are allowing us to connect different thrust actuators for example this particular one Su 6X MD has the low thrust option where we have an actuator that can drive up to about 300 lb force of trust anything related to intermediate web guiding this will be the actuator for that this particular actuator can draw up to 4 amps of CCT when we go to a higher prust the part number is going to be a little bit different it's going to be s use 6X mxd where the X relates to the extra in that we need and that particular one can drive up to about 500 lb of thrust so a shifting stand with the total weight um of no more than about 5,000 lb can be driven with that actuator the only difference would be the connector here would be a little bit different on this side now it'll be a high thrst a high current connector and then for that particular actuator we would also need a different power in the Dual rear power input will have 7 amps up to 7 amps for that we also can do up to 48 H VC

---

# SCU6x Controller Functionality of Sensor Orientation

URL: https://r2r.tech/videos/scu6x-controller-functionality-sensor-orientation.md

This video demonstrates the SCU6x Controller's Sensor Orientation feature on the Operator Interface. Learn how this feature provides flexibility in web guiding applications by allowing operators to easily switch sensor positions and enable/disable sensors. Key Benefits: Adaptability to Different Jobs: Easily switch between guiding edges for different tasks without physically moving the sensor. Support for Varying Web Widths: Efficiently manage multiple web widths by enabling specific sensors at designated positions. Simplified Operation: The controller automatically detects and utilizes enabled sensors, streamlining the guiding process. The Sensor Orientation feature of the SCU6x Controller enhances efficiency and simplifies web guiding operations in various industrial scenarios.

## Transcript

[Music] so one of the key things why we have this functionality is that you want the operators to have the flexibility to move the sensor from one side to another side and have a simple couple of steps to switch from one edge of the web to the other edge of the web there are scenarios where when they're running one job they want to write on one Edge and when when they're running another job they want to run on another Edge also we have the reason to enable and disable the sensors because there are situations where they might have two different locations where they are dating the web and for two different products so for example let's say they are running uh a 20in wide web for one job and a 30in wide web on another job instead of moving the sensors from one Edge to the other J Edge when the wig changes The Operators can just have two sensors installed at two different cross machine Direction position and then just enable that sensor for that job for one time and then enable the other sensor for the other job at the other time our controller will automatically figure that out whatever the sensor is enabled or how many ever sensor is enabled that's what is going to be used for guiding purposes and it will take care of off everything else automatically so that's the reason why we have the ability to enable and disable the sensor

---

# SCU6x Controller Gross Guide Point Reset

URL: https://r2r.tech/videos/scu6x-controller-gross-guide-point-reset.md

Introduction to Gross Point Adjustment

In this video, we demonstrate how to perform a guide point adjustment on the SCU6x Controller. Specifically, we focus on the technique known as a gross guide point adjustment. By simply dragging the reference bar to the desired position, users can effortlessly move the guide point without affecting the web. This process is clarified step-by-step to ensure you can make precise adjustments with ease. Watch to learn more about optimizing your SCU6x Controller's performance with this straightforward method.

00:00 Introduction to Guide Point Adjustment
00:08 Gross Guide Point Adjustment Explained
00:11 How to Move the Reference Bar
00:20 Gross Guide Point Adjustment

## Transcript

now if you really want to move the gate Point without the web you still do that by dragging that and doing [music] that and we call that as a cross gate point adjustment so you can just grab that reference bar and move it do whatever you want and press accept and that will do that so that's what we call as a gross gboard adjustment

---

# SCU6x Controller Interface Home Main Screen Tutorial   Part I 

URL: https://r2r.tech/videos/scu6x-controller-interface-home-main-screen-tutorial-part-i.md

Comprehensive Guide to SCU6x Controller: Home Screen, Sensors, and Troubleshooting Tips

Join us for an in-depth exploration of the SCU6x controller. In this detailed demo, we will cover the operator interface screen, available buttons, and the connections. Learn the critical troubleshooting tips, including the importance of the heartbeat LED and web detect indicator. We'll also guide you through the firmware versioning, sensor configurations, and web position indicators. Lastly, discover how to switch sensors easily and reset the guide point for different job setups. Perfect for operators looking to optimize their use of the SCU6x controller.

00:00 Introduction to SCU6x Controller
00:16 Exploring the Home Screen
01:03 Heartbeat and Firmware Indicators
04:20 Web Position and Detect Indicators
05:58 Sensor Configuration and Orientation
18:56 Guide Point Adjustment
23:30 Controller Setup for Guiding and Actuation

## Transcript

[Music] hello everyone today we're going to take a deep dive into the SCU 6X controller I have a a demo setup here with the um SCU 6X controller in the back and a couple of sensors connected to it what we're going to do is look at the home screen or the main operator interface screen and we're going to look at what are the things that are available in that screen how an operator can use to kind of understand what's going on with the system and also use it for troubleshooting purposes and things like that we have the seu 6X screen right here so I'm going to zoom in to that and we're going to do a deep dive into all the buttons that are available in the operator interface we'll talk a little bit about the connections as well and then I'll finish up with what are some of the common troubleshooting ideas or tips based on the information that is available on the home [Music] screen first and foremost thing that I want to point out is what we call as the heartbeat LED this is basically the bottom left hand corner and this particular LED is blinking between red and green in the SCU 6X there's actually another led a physical LED that's available on the side which is labeled B zero and that will also blink between green and no no light so we call it a heartbeat which means that this is very critical and we want to make sure that this led is blinking all the time so this is again one of those things which is used for troubleshooting purposes if you call us and say hey something is happening nothing is working when we touch the um operator interface the first thing that we're going to ask is that hey is this heartbeat LED blinking and what it is indicating is that there is the program the motherboard is running and the motherboard is communicating back to the operator interface and and the motherboard if there is no communication between the display and the motherboard then this led would stop blinking so that's a good good indication to say that there's something wrong with just the touchscreen operator interface the motherboard is still working fine [Music] the next thing that we focus on is going to be this top right hand corner it says B2 4.2a it's kind of hard to see for you but believe me there is a firware number there so that is basically the firmware number or the firmware version number for this particular controller this is another common thing that you would ask especially for troubleshooting purposes what that fir number and if that doesn't give us enough information we do also have another shmer number on the back which is printed on our product label and that is for if we want to get deep down into it so when do we change these firmare numbers on the top here uh anytime there is a significant change where we are doing a bug fixing we would change that firware number and also anytime there's some UI changes so any anything with related to the buttons adding a new screen or removing a a different screen we would change that firmware number so in general we don't remove any features we only add features to our system so most often if you have a product manual that says version 4.2a most likely it will be applicable to a version 4.1 or 4.0 as well another note if you're familiar with our seu 6X controllers or if you are familiar with roll to roll Technologies we had an seu 5 controller before and now we have the SCU 6 the SCU 6 all start with version 4. something and SCU 5 all start with version 3. something that is the firm number the next thing we want to focus on is this bar right there which is called as the web position indicator and uh depending upon what sensor we have connected the bar will show the position of the web and so for example if I put the web there you can see that it's showing that position and the way the web moves depends upon other parameters but that's indicating the web position another key thing on the bottom left right above that heartbeat LED is called a web detector indicator right now you can't see anything it's gray but when I present the web there it turns green when I take it off it's gray so that is what we call as a web detect indicator when when you are under normal operating conditions that uh should be green all the time I'm going to make it kind of flicker back and forth just by moving the web closer or farther away from that sensor and you don't want that to be blinking like this that's not a good sign and then the first thing that we are going to look at is is the sensor installed properly is there something in the background on the sensor that we need to consider and and is it angled properly so that it's not picking up something and losing the web position both heartbeat and web detect indicator are two important things that are available on the home screen on the SCU 6X we have these two buttons which say sensor one and Sensor 2 and essentially what it is is that these allow us to configure our sensors however way we want our sensors are one-sided which means that we could have the web come in from either direction and this is what we call this a sensor orientation so it could come from this way where it's coming from the right to left or it comes from left to right so our controller can handle either of those conditions we just need to be able to tell it how to do it for all our sensors the orientation is defined this way for the 48 mm sensor there's actually a label that says left and right so if you look at here you would see that there is a right and a left indication that means that if I I pressing a we and I see that left label that means we are looking at the left edge of the web if we come this way we are looking at the right edge of the web and that's how we know the orientation for the 48 mm sensors for anything from 96 to 960 the orientation is this way where that keyb comes out that is going to be our right and where the cable is not present that's going to be our left so this region is going to be our right and this region is going to be our left so if we present the we and we see the left Edge like what I'm showing here so that's going to be configured as a left Edge orientation and if we present the web like this where we're looking at the right edge of the web then that's going to be the right Edge so these bars these green squares are indicating how that particular sensor is Con configured if you press that once it's called a todle between the states I'll do that again so the the four states that are available are no sensor which is what this is both those LEDs are turned off if I press it once sensor one is configured as left left sensor and that's what this is and if I press it another time it will go to Center sensor which means that you have both edges of the web if I press it one more time it's going to go to the right sensor and if I press it one more time I can disable the sensor all together so that's what that button is allowing us to do is to configure the orientation of the sensor whenever we press that button one key thing to note is that if we have this sensor C able disconnect it then this button will only have two states one is enable and the other one is disable because it's either enables the sensor or disables the sensor the controller automatically knows that there's no sensor connected to it so it's not going to toggle between the states it's just going to reable it and disable it so when I reconnect this back in then we have the ability to get all four states right now the sensor is disabled I have it connected now it can go to the left sensor Center sensor right PR disable likewise you can do the same thing for the sensor to and for now I'm going to disable both sensors and just enable right sensor as left Edge the sensor button allows the operator to go from one state to another [Music] state so one of the key things why we have this functionality is that you want the operators to have the flexibility to move the sensor from one side to another side and have a simple couple of steps to switch from one edge of the web to the other edge of the web there are scenarios where when they're running one job they want to write on one Edge and when when they're running another job they want to run on another Edge also we have the reason to enable and disable the sensors because there are situations where they might have two different locations where they are guiding the web and for two different products so for example let's say they are running uh a 20in wi web for one job and a 30in wide web on another job into of moving the sensors from one Edge to the other Edge when the wig changes The Operators can just have two sensors installed at two different cross machine Direction position and then just enable that sensor for that job for one time and then enable the other sensor for the other job at the other time our controller will automatically figure that out whatever the sensor is enabled or how many other sensor is enabled that's what is going to be used for guiding purposes and it will take care of everything else automatically so that's the reason why we have the ability to enable and disable the sensor there are also applications where we have one actuator guiding the web and there might be a scenario where we want to guide the web with one sensor in One Direction and the other sensor in another Direction these are commonly seen in machines where the web can can go both in forward and reverse Direction especially in an unwind or a rewind you can have it configured where in One Direction the the system behaves like an unwind with a sensor installed on the fixed machine frame and then when it goes in the backward Direction the same system behaves like a rewind where the other sensor would be installed in a chasing kind of configuration in those cases we can switch between the two sensors pretty quickly just from the home screen without us having to navigate to multiple screens to enable or disable the sensor so that's the functionality for the sensor orientation buttons so I will present the web right now and we're looking at the left edge of the web and as you can see that the white region in the web position indicator is representing the web and the black region is representing the uh backdown or Mo so as I move back and forth if I have the Lage configured for the orientation then as I move from right to left the web position is going to increase from right to left just like what you see on the scen if we change that orientation to right the bar automatically switches and it goes in the other direction just like what beings right I'm going to disable it and enable this sensor but I'm going to do a center orientation for that this means that we have a a sensor that is wide enough that it can see both edges of the wi the first thing that you're going to notice is that there is a green line in the middle and that line is indicating the center position um of f sensor and when I present a WEP here then you're going to see both edges so that that the left side is dark the right side is dark the middle region which represents the web is going to be white and then the green line is the center line of the we and that's what it's showing there it's being moved from left to right so when we do Center guiding the reference or the edge position for that guiding is indicated by this green line right there so in this case it's Center the controller automatically knows that if you set it in Center then it needs to look at the middle position of the web if we put it back to left mode it's going to look at the left Edge and the green line is still there and it's kind of hard to see but it's at the leftmost point of the white region and that's what we call as um The Edge position so this is what is used for control now in respect to of what we have it does change my Edge position and also notice that I only have one edge of the web or I have both edges of the light break here but it's only looking at the left Edge so when I have this uh small piece of paper where I see both edges if it is configured for the left Edge it will only pick up the left Edge and if I do Center you can see both edges and if I do right it'll only pick up the rage and that's how it works so it doesn't matter if the web is wide enough or wider than the sensor field of you how we configure the orientation will dictate what Edge the is used for guiding or uh control furnaces so there are situations where we would have to use two sensors and uh if the sensor is not wide enough or the web is much wider than our sensors then um we would have that scenario I have this sensor two which is this sensor I have that configured for left Edge in sensor one I have that configured for Frid day and then now if I present the paper that this partly seen by One sensor and partly seen by other a sensor then we're going to see that and then again the the green line indicates the center line position and then the right edges and lighter the left edges indicate the edges of the W one of the things that I want to point out is that in uh normal situations we will always ask that uh when you do Center guiding with two sensors that you use two of the same sensors with the same measuring range and same resolution it just makes it easy and it avoids any confusion here I just wanted to show that it's possible to use different sizes of sensors when you do centri guiding uh what where does this confusion come from just to show on the screen what I mean by that we have one sensor configur to left and the other sensor configur to the right and when we do that the screen is going to be split up into two regions or the web position indicator is going to be split up into two regions if I present the web on just one sensor so I'm presenting it on sensor one which is config as right sensor you can see that only that great half is being updated likewise only the left half is being updated and then when I have a web wide enough it sees both sensors then the portion of the left half corresponding to the left sensor and the portion of the right half corresponding to the right sensor is only going to show up there so the conclusion arises mainly because we have one sensor that is almost six types or or eight types wider than this sensor but we only have the same 50% viewing area on the top so when we move just a little bit on the bottom sensor it seems like it's moving a lot whereas when we move little bit on the top the the right left sensor then it seems like it's moving a little but in reality it's moving the same amount but it's just that on the screen we don't have we're not scaling that based on the two different sensors range so that's the difference so we covered the main things with the sensors in terms of the orientation how the web position is indicated how you get the web detect signal and things like that one other key feature that we have is what we call as reset G point this enables our operators to switch from one width to another width without moving the sensor itself in a traditional application where you have a narrow band sensor that takes about 6 mm that's looking at one edge of the web if you change from one web WID to another web WID then what they have to do is they have to physically move the sensor that's like having a rail and move it there and the other thing that they do is that they might have to do a they they might have a micrometer or a fine adjustment to move that sensor just a little bit based on what the guide point is all of these things could be done digitally from our home screen and that's what I'm going to show show you next to show the gide point adjustment uh I have once in are connected to the controller and enabled and it's set to the left sensor configuration so you can see that when the web moves here it's the left sensor configuration now what we want to do is we want to change the guide point let's say we are running a different job at a different location instead of moving the sensor we want to change the GU point so let for example this is the web and we have traded the web and this is the correct location or this is the ideal location where we want the new reference to be what the game point to be all that the operator needs to do to reset to this gra point is to press that button and accept and that will change the gr point so the gr Point offset on this home screen is showing us how far away from the middle is the current gate point and right now it's exactly in the middle of the sensor speed with view in t zero and Visually it's also indicated by this bar right here and this is exactly in the middle of the field of view of that now if we go to the left of the guide point and let's say this is our new reference and the operators instead of moving the sensor they can move the DAT point so all that they need to do is press the reset G point and say accept now we can see that the DAT Point number moved there and also this dat Point bar move there you know so that one more time let's say they want to use this current web position as the reference then press reset take point and accept and it moves there so this number right here the G Point offset what is showing is that what is the offset from the middle and and that is indicated in the so that's to reset the gate point now if you really want to move the gate Point without the web can still do that by grabbing that and doing that and we call that as a cross gate point adjustment so you can just grab that reference bar and move it to whatever you want and press except and that will do that so that's what we call as a gross great point adjustment and then we don't allow you to change the guide point all the way to one side like that so if we do that it will go only to about a certain amount and that's just for safety purposes and then just to be sure that somebody doesn't intend to do something what we also do is that if somebody press this button and let's say that it it shows the reset gate point to a new gate point and if you didn't intend to do it all you have to do is just leave it alone for a little bit and then that will automatically reset unless you press accept any change to this accidental change it will show that the the current or intended gate point is minus 16.7 but if you don't accept it it will go back to its original gate Point reference whatever you had it for so just to avoid any accidental changing uh we do that and it's the same thing with this reset gate point if you press that button unless you press the accept anything that we do here is not going to change the gate Point unless somebody intentionally says that that's what they want to do we want to make sure that we have everything set up uh properly where we're able to see the web now in the following we will look at how to set up the controller for guiding or actuation the operator can use that uh home screen to put the web guide in Auto put it in manual and also be able to manually jog it left and right and then also do any Servo centering operation or things like that that's what we're going to see next so I do have a couple of things set up here so I have one sensor that is set up to look at the left edge of the web that's shown here since the one is connected and it's set up to look at the left edge of the web and in this particular placee I don't have an actuator connected but I can still show most of the items there through that interface so these buttons on the bottom these are the buttons where somebody could put the webc an auto or manual or jog or Servo Center we'll go through this one by one the Jog and the servo Center buttons or what we call as momentary [Music] buttons this one is basically Auto or manual when it's in red it's in manual mode and if we press it and if it changes to Green it's in automatic mode and um as you can see it's seeing the web right there when I move the web you can see that the web is oscillating here and these are J left and Jog right and then the S Center e

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# SCU6x Controller Interface Tutorial   II - Actuator / Web Guiding Controls

URL: https://r2r.tech/videos/scu6x-controller-interface-tutorial-ii-actuator-web-guiding-controls.md

The second part of the SCU6x Controller Tutorial explores the SCU 6X controller with a focus on its functionalities and capabilities not covered in the first part. Learn how to navigate the home screen, perform manual jogging, set servo centers, and operate in automatic web guiding mode. Discover the safety features, guide point adjustments, and the differences between edge guiding and center guiding using sensors. This tutorial provides a comprehensive overview of the controller's interface and its operational capabilities.

00:00 Introduction to SCU 6X Controller
00:36 Understanding Actuator Options
02:10 Home Screen Functionalities
02:26 Actuator Position and Jog Commands
04:21 Servo Center and Jog Buttons
07:44 Manual and Automatic Web Guiding
11:53 Fine Guide Point Adjustment
15:10 Resetting Guide Point to Zero
19:00 Center Guiding with Sensor

## Transcript

hello everyone this is Aran sadri from Roll tooll Technologies today we're going to look a little bit more about some of the other functionalities on the home screen or the operator interface screen and specifically related to actuators so what we have today is our SCU 6X controller and this is SCU 6X MD and we have one sensor connect Ed to it then in the motor port we have an actuator connected to it right there seu 6X MD and there is another option seu 6X mxd both of these options are allowing us to connect different thrust actuators for example this particular one Su 6X MD has the low thrust option where we have an actuator that can drive up to a about 300 lb fors of trust anything related to intermediate web guiding this will be the actuator for that this particular actuator can draw up to 4 amp of Curr when we go to a higher prust the part number is going to be a little bit different it's going to be SCU 6X mxd where the X relates to the extra in that we need and that particular one can drive up up to about 500 lb of crust so a shifting stand with the total weight um of though more than about 5,000 lb can be driven with that actuator the only difference would be the connector here would be a little bit different on this side now it'll be a high thrust a high current connector and then for that particular actuator we would also need a different power in the Dual re power input will will have 7 amps up to 7 amps for that we also can do up to 48 H DC everything that the operator need should do on a day-to-day basis can be done from the home screen for example things like putting the web guide in automatic or manual joging the web guide back and forth and then putting the web guide in the C Center mode the first and foremost three with the with regard to the actuator is this actuator position bar this bar is going to indicate the position of the actuator in this position is the electronic position that is being read by our driver right now the actuator is in the middle as we jog the web guide you should see that actuator position to be changing and then there's also visual indication of when the actuator is getting new near to its extreme position and that's indicated by this um yellow bar and then if you keep moving it turns red which means that there's really not much left in the actuator position so this is indicating that it's reaching its stroke Lane now in terms of the stroke of the actuator these are all electronic limits that we have in the controller in subsequent videos we will talk about how one can change those limits based on what the actual actu stroke T takes like that so this is the if I press this one you should be able to see that go draw the left and it'll do the same thing if it goes to a certain position where it's getting closer to its extreme it's going to be yellow the keep going called the dead red and then if it's off the read even if the actuator presses this button now nothing happens and that's because the actuator has reached this limit there so it will not move in that direction however it will move in the other direction so that's the actuated position more then we saw the jog left and Jog right command there now if you want to put the web guide in Servo Center basically means different things for different types of web guyses but essentially putting the wind guided a U pro position so that it add enough stroke to go on either side um of the servo Center position then you can press this button and this button uh it's a single press button and when you press that it will bring the web guide or the actuator to its home position or what we call as the zero position so one difference between the jot buttons and the servo Center buttons are that these jot buttons or what we call as momentary buttons that means that you need to keep pressing there for the actuator to keep jogging as soon as you let go the actuator is called a stop joging in that Cas both of them are like that um Circle Center is more like a push button and it will actually tell you the Stak in which it is there for example if I JN it and then if I put it to server Center this is in the servo Centric state so it's going to be green and and until the Sero center operation is done it will stay green and once the oper operation is done it will turn back to Red so there's no need for us to keep pressing then button it's a one time push button C so click just to give you this again when you press the servo center it's going to uh bring the actuator to its home position once the operation is done once it reaches the home position it's going turn back to um red again there are different ways in which we could do the servo centering operation which will be handled in a future video essentially depending upon whether we are just using an electronic limit or if we're using a physical proximity sensor to do that so those are for the jog left Jog and turbo Center one other thing that we have is basically this actuator position bar if you press that motor icon on the home screen this let you see a bigger view of the AG regor position K in this case if the web CAG moves back and forth you can see that actuator bar will move back and forth one thing to note about this Servo center button is that this has a different functionality than what it is in the home screen so we recommend that you take a look at the subsequent videos about this functionality before using this so one other option that we have is that if if the operators are not allowed to change the servo Center position then in that scenario the controller can be locked in such a way that the operator cannot change that simple Center position then if you click on this motor icon now it'll only show you the jog length and the jog button and it won't show you that re reset Servo center button so the operators can just view the actuator position and not be able to reset the C Center position so that's the difference between having that enable and disable this is about moving the actuator manually to facilitate loading and unloading the roll but the real thing with our system is basically it does guide the we automatically to its desired okay this is about moving the actuator manually to facilitate loading and unloading the r but the real thing with our system is basically it does guide the we automatically to its desired position so just to show you that let me present the we put the web guide in automatic mode so as you remember that the gray bar in the middle is basically our G point and if we are on one side of the G point the aerators will move one way if we are the other side of the G point the actuator for M be way and it's that's out it's stating the web and then the actuator position bar indicates what the stroke of the actuator is and obviously once it reaches its stroke it doesn't matter how much error we have the accelerator is not going to move in that direction but if the eror F on that direction then the actuat is willable and he that in for BL so this is the automatic feature of our web guing system and right now I'm using a single edge to gu the material and it doesn't matter if I have one Edge or two edges it will do the same thing so one other feature that we have is that we have an automatic web to Tech signal in a previous video we talked about this which is that web detect signal we can use that information to stop the actuator for movie even while it's in automatic mode if the we breaks so just illustrate that I'm going to show then and sping the web Ming toward and you can see that actuator position might keep the web braks and there's no web in front of it then the actuator stay stays put and this is what we call as lock on Lost Edge essentially a functionality that ensures that the actuator doesn't get cocked to one side or the other if there is no web in the fielded view of the CER and as soon as the web comes back it's going to start dating it when there is a web break it's called start and hold it positioned and this is essentially for detecting the uh web break and then making sure to stop the actual in its current position so that it doesn't disrup the the operation once the TR web is turnning back in okay in a previous video we looked at the G Point offset basically how to reset the G Point again that is useful when you have a white sensor and you uh present the web like different notations so just to go for that one more time here I've got a white sensor here and the web is positioned at some point I'm going to go in and reset gate Point except that's there and if I put the we p in automatic it's going to stay in that position and if I need to change that dat point to a new location when it's in manual and we can still do that the we isit this new location and I'm going to do the reset cway accept and when I put it in auto in scr the actuator is staying in position because the web is at the night Point location and if I move the web to one side part the other it's little stop it's going to die with respect to that c one that's the briet cake one now there are situations where you are guiding the web you got it at the SP but you want want to make a fine adjustment and with the traditional sensors there might be something like a micrometer and an operator needs to reach in and try to adjust that screw on the micrometer to move it back and forth to do what is called as a fine dat point adjustment so think of it like a lamination process you got the wind align guiding but you want to change that gate point just a little bit you don't want to make too much of an adjustment and you want to do that while the Wim is running and that is what we call as a fine gate point adjustment how to do the fine gate point adjustment right now the G Point offset isus 119 mm and if I want to change that just a little bit then I if I want to increase that I can press that increases that the web guide is not going to move until it goes away from the B so just to illustrate the SP thing now it reach the limit for the dead man and it's continuing there that's our fing point adjustment so this allows you to be able to M uh make very fine adjustments to the guide point again the plus arrow allows you to increase that gate point and minus Arrow allows you to decrease that gate Point that's what is called it a fine gate Point government and this adjustment can be done only when we are in automatic mode and then each press of B will take1 mm I think that's what it looks like1 mm to move the gate plan one of the reasons why we have this icon where the operators can see of either view of the actuator position is those scenarios where an operator is farther away from our controller and they want to make some subs sequent adjustments to the position or essentially the DAT Point using the M operator interface but they want to make sure that adjusting the gate point doesn't make the actuator to reach its limit that's one of the reasons why we have that right now the web guide is in automatic mode and the web is staying there it's not moving but if I moved the web gu you can see that you can the actuator bar changes if this is just a bigger view of what we had in the home screen and the reason why is uh a bigger view is allowing The Operators to see this interface from a longer distance while they're making adjustments to other parts of the machine so that if the actuator reaches its limit it's pretty evident and they can make adjustments to the other part of the machine so that it doesn't the guy doesn't lose its stroke uh during guy this button you can Beed either in automatic mode or in manual mode okay one other feature in terms of resetting the G point hset on that we have is there are some occasions where you want to reset it to zero and this has to be done with extreme care and only people who know what they're doing should be able to do this and that's because this is very powerful and changes the date Point immediately so there might be some occasions where you want to absolutely reset pick 8. to0 the best way for us to do that is while it is in automtic did you press the servo center button it's going to show you that hey you want to reset the G point to zero do you want to accept it obviously if I accept it the web visit different location it's going to go all the way to one side the actuator is going to go all the way one side because it's trying to correct for the we position again when you're in automatic mode if you press this Servo center button then it would allow you to reset the G point if I press accept the T point is going to be in the middle now Bally the actuator is newly because it's trying to bring the web to its um to the P Point reference that's the way in which you could reset the K point to Z one other thing that happens when we put the web guide in automatic mode is that this tools icon is going to disappear um I'll do that and you can notice that the proven automatic the tools icon disappears so essentially when the web guide is in automatic mode the operator cannot go in and change any parameters related to the edge Center or contrast or anything related to the speed the gate none of those parameters could be changed while the webite is aide just a safety just so that we don't intentionally cause any cor when the webc isn't so that's why that one is the only screen that the aerator can navigate to is going to be this screen and that's going to show you the actuator position in a bigger view the operator cannot go into any other screen while in automatic mode the other thing that you're going to notice when the web guide is in automatic mode is take a look at these sensors so I put it in automatic mode the buttons so those buttons are disabled again same idea when you are an automatic we don't allow the operator to change the orientation of the sensor so if they can't enable or disable the sensor they cannot switch from one sensor to another sensor all of these things have to be done a pror before they put it in the automatic one and then again reset dat point if you put it in automatic mode that disappears so they won't be able to make any big adjustments to the G point the only exception to that is to reset that gate point to zero as the only that they can do and that's the reason why we say that when you do a reset CR point to zero to be really careful um and do only and that's the reason why we have that accept button so if somebody presses St by the St we don't necessarily have to take that command unless the operator intentionally presses accept if it doesn't press the accept button then it'll go back to the previous gr point so the next thing that we're going to look at is we showed how to do Edge guiding with a sensor now we're going to do how to do cting with the sensor so I'm going to change this orientation sensor orientation so that sensor one can detect voltages of the web and that's what it it's detecting and as you remember from our previous video when we do c and the guide the ref reference for the web is not based on one Edge actually based on the two edges so that's what is presented by this green bar so if I move the center line of that web to this green bar to this point box act and then put it in Auto then when that centrer line changes position that's how we're going guided essentially Center guide so what is the advantage of Cent gu is that when you hand weight changes you don't have to move the sensor as long as your G Point offside is the right loation so for example if I put another web that's wider you can do a on the Fly wi change with one to another web wi and it will automatically guide and you wi in a C position and that's one of the biggest advantage with a center diing solution is that when the wit changes let's say it have some varability in your brid your web will always be presented to the center line of the machine as long as the center as long as the sensor is set up properly then you can bring it to that Center Line position with respect of the quarter in or half an inch web with L so in terms of Center guiding Center position this represent by the green bar and then the web guide is going to keep that Center position um I'm moving the actuator back and for so that green bar aligns with that gray gray P point and cence as it should so that's the main difference would be Edge tiing and Center Tiding again you still have that option of web Brak so the web braks it will stop actuating and it will start back actuating but the web this dressing and then obviously it's going to do it it's going to stop until the web reaches its B Point reference if the WID changes doesn't matter as long the red WID the Cent line that so that's Center D with with a single sensor

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# SCU6x Controller Operator Lockout During Automatic Mode

URL: https://r2r.tech/videos/scu6x-controller-operator-lockout-during-automatic-mode.md

In this video, we explore the features and safety measures of the web guide controller when set to automatic mode. Key highlights include the operator lockout during automatic mode of the controller, which automatically disables the tools icon and various parameters like the edge sensor, contrast, speed, and gain. We also examine the limitations imposed on the operator's control, such as the inability to change sensor orientation or switch sensors. The video explains why these restrictions are in place and how the guide point reset functions, emphasizing the importance of careful usage and the implementation of an accept button to prevent accidental changes.

00:00 Introduction to Automatic Mode
00:15 Operator Restrictions in Automatic Mode
01:03 Sensor and Button Limitations
01:36 Guide Point Adjustments
01:55 Safety Measures and Accept Button

## Transcript

one of thing that happens when we put the web guide in automatic mode is that this pools icon is going to disappear um I'll do that and you can notice that the proven automatic the tools icon disappears so essentially when the web guide is in automatic mode the operator cannot go away and change any parameters related to the edge Center or contrast or anything related to the speed the G none of those parameters could be changed while the webite is not attack just a safety just so that we don't intentionally cause any cor when the webc isn't on so that's what that one is the only screen that the operator can navigate to is going to be this screen and that's going to show you the actuator position in a bigger view the operator cannot go into any other screen while in automatic mode the other thing that you're going to notice when the web guide is in automatic mode is take a look at these sensors when I put it in automatic mode the buttons so those buttons are disabled again same idea when you are an automa we don't allow the operator to change the orientation of the sensor so if they can't enable or disable the sensor they cannot switch from one sensor to sensor all of these things have to be done a pror before they put it in the automatic one and then again reset G point if you put it in automatic mode that disappears so they won't be able to make any big adjustments to the gate point the only exception to that is to reset that gate point to zero as the only thing that they can do and that's the reason why we say that when you do a reset gr point to zero and be really careful um and do only when you needed and that's the reason why we have that accept button so if somebody presses that by the St we don't necessarily have to take that command unless the operator intentionally presses accept if it doesn't press the accept button then it go back to the previous gr point

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# SCU6x Controller Reset Guide Point to Zero

URL: https://r2r.tech/videos/scu6x-controller-reset-guide-point-zero.md

This episode provides a detailed explanation on how to reset the guide point offset to zero in automatic mode using the servo center button. The process is highlighted with caution due to its powerful impact on the guide point and web position, emphasizing that only knowledgeable users should perform this operation. Viewers learn how pressing the servo center button prompts a confirmation to reset the guide point, and accepting it results in moving the actuator to correct the web position to the new guide point reference.

00:00 Introduction to Guide Point Offset Resetting
00:15 Importance of Caution in Resetting
00:33 Automatic Mode Reset Procedure
00:50 Accepting the Reset and Its Effects
01:00 Final Steps in Resetting Guide Point

## Transcript

okay one other feature in terms of resetting the G Point how that we have is there are some occasions where you want to reset it to zero and this has to be done with extreme care and only people who know what they're doing should be able to do this and that's because this is very powerful and changes the G Point immediately so there might be some loation where you want to absolutely reset pick 8. to0 the best way for us to do that is while it is in a Ned did you press the servo center button it's going to show you that hey you want to reset the G point to zero do you want to accept it obviously if I accept it the web isit a different location it's going to go all the way to one side the actuator is going to go all the way one side because it's trying to correct for the web position again when you're in automatic mode if you press this Servo center button then it would allow you to reset the T point if I press accept the T point is going to be in the middle now basicly the actuator is newly because it's trying to bring the we toward its um to the gr Point reference that's the way in which you could reset the G point to see

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# SCU6x Controller Resetting the Guide Point with a Wide Sensor

URL: https://r2r.tech/videos/scu6x-controller-resetting-guide-point-wide-sensor.md

In this video, we revisit the concept of the guide point offset and how to reset the guide point using the SCU6x Controller. This technique is particularly useful when working with wide sensors and handling the web at different positions. The video walks through the steps of resetting the guide point, both in automatic and manual modes, ensuring precise guidance of the web. By following these instructions, you can maintain the correct positioning and handling of your web material, helping to enhance operational efficiency and accuracy.

00:00 Introduction to Guide Point Offset
00:25 Resetting the Guide Point
00:29 Automatic and Manual Guide Point Adjustment
01:06 Conclusion and Summary

## Transcript

okay in our previous video we looked at the guide point offset basically how to reset the G Point again that is useful when you have a white sensor and you uh present the web like different locations so just to go over that one more time here I've got a white sensor here and the web is positioned at some point I'm going to go in and reset great Point except up there and if I put the we p in automatic it's going to stay in that position and if I need to change that date point to a new location when it's in manual and we can still do that the web isit this new location and I'm going to do the reset cway accept and when I put it in Auto in SC the actuator is staying in position because the web is at the point location and if I move the web to one side part the other it's little stop it's going to die with respect to that and that's the re cway

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# SCU6x Controller Screen for Enhanced View of the Actuator Position

URL: https://r2r.tech/videos/scu6x-controller-screen-enhanced-view-actuator-position.md

In this episode, we explain the functionality of an enhanced operator interface that provides a larger view of the actuator position. This feature is particularly useful when operators are working at a distance from the controller, allowing them to make precise adjustments without the actuator reaching its limit. The video demonstrates how the web guide operates in automatic mode and explains the benefits of being able to view the actuator bar from different parts of the machine. The button to access this interface can be used in both automatic and manual modes.

00:00 Introduction to Actuator Position Viewing
00:13 Importance of Remote Operator Interface
00:39 Automatic Mode and Web Guide Movement
00:54 Enhanced Visibility for Operators
01:19 Manual and Automatic Mode Button Access

## Transcript

one of the reasons why we have this icon where the operators can see a the view of the actuator position is those scenarios where an operator farther away from our controller and they want to make some subsequent adjustments to the position or essentially the date Point using the the mode operator interface but they want to make sure that adjusting the G point doesn't make the actuator to reach its limit that's all of the reasons why we have that right now the web guate is in automatic mode and the web is staying there it's not moving but if I move the web guate you can see that you can the actuator bar changes if this is just a bigger view of what we had in the home screen and the reason why is uh a bigger view is allowing The Operators to see this interface from a longer distance while they're making adjustments to other parts of the machine so that if the actu reaches its limit it's pretty evident and they can make adjustments to the other part of the machine so that it doesn't guide doesn't lose its stroke during guy this button you can reach it either in automatic mode or in manual mode

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# SCU6x Controller Servo Center

URL: https://r2r.tech/videos/scu6x-controller-servo-center.md

In this episode, we'll explore the functionalities of the SCU6x controller, focusing on the different operations of jog buttons, and the servo center feature. We'll explain how the servo center button positions the web guide in neutral and how this differs from the momentary jog buttons. The video also covers indicator states for the servo center operation, including how it transitions from green to red. Future videos will detail more about the methods for servo centering, including using electronic limits and physical proximity sensors.

00:00 Introduction to Web Guide Servo Center
00:35 Understanding Jog Buttons vs Servo Center Buttons
00:55 Operation and Indicators of Servo Center
01:41 Conclusion and Future Topics

## Transcript

now if you want to put the web guide in Servo Center basically means different things for different types of web gues but essentially putting the web guide in a newos so that it has enough stroke to go on either side um of the servo Center position then you can press this button and this button uh it's a single press button and when you press that it will bring the web guide or the actuator to its home position or what we call as the zero position so one difference between the jog buttons and the servo Center buttons or that these jot buttons or what we call as momentary buttons that means that you need to keep pressing there for the actuator to keep jogging as soon as you let go the actuator is going to stop jogging in that case both of them are like that um Ciro Center is more like a push button and it it will actually tell you the Stak in which it is there for example if I johned it and then if I put it to server Center this is in the servo Centric state so it's going to be green and until the servo center operation is done it will stay green and once the operate operation is done it will turn back to Red so there's no need for us to keep pressing that button it's a one time push button C so click just to give you this again when you press the servo Center it's going to uh bring the actuator to its home position once the operation is done once it reaches the home position it's will turn back to um reding there are different ways in which we could do the servo centering operation which will be handled in a future video essentially depending upon whether we are just using an electronic limit or if we're using a physical proximity sensor to do that so those are for the jog left Jog and turbo Center

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# SCU6x Controller Servo Center Operator Lock

URL: https://r2r.tech/videos/scu6x-controller-servo-center-operator-lock.md

In this video, we explore an important feature of the SCU6x Controller related to the servo center position. We discuss a scenario where operators are not permitted to change the servo center position and how the controller can be configured to lock this setting. By clicking on the motor icon, operators will only be able to see the jog left and jog button options, while the reset servo center button will be hidden. This feature ensures that operators can view the actuator position without being able to reset the servo center, thereby facilitating manual movement of the actuator for loading and unloading rolls. Additionally, we highlight the automatic web guiding capability of the system to its desired position.

00:00 Introduction to Servo Center Position Lock
00:15 Motor Icon Functionality
00:24 Operator Restrictions
00:30 Enabled vs Disabled States
00:34 Manual Actuator Movement
00:42 Automatic Web Guidance System

## Transcript

so one other option that we have is that if if the operators are not allowed to change the servo Center position then in that scenario the controller can be locked in such a way that the operator cannot change that simple Center position then if you click on this motor icon now it'll only show you the jog length and the jog button and it won't show you that reset Servo center button so the operators could just view the actuator position and not be able to reset the C Center position so that's the difference between having n enable and disable this is about moving the actuator manually to facilitate loading and unloading the RO but the real thing with our system is basically it does guide the we automatically to its Desir

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# SCU6x Controller Set Up for Guiding and Actuator

URL: https://r2r.tech/videos/scu6x-controller-set-guiding-and-actuator.md

In this video, we demonstrate the setup process for the SCU6x controller, focusing on its functionalities for guiding and actuation. We will explore how the operator can use the home screen to switch the web guide between auto and manual modes, jog it manually left and right, and perform servo centering operations. The video includes a practical setup with a sensor configured to monitor the left edge of the web, illustrating various features through the interface even without an actuator connected. Stay tuned to understand these essential operations.

00:00 Introduction to Controller Setup
00:09 Home Screen Functions
00:15 Manual Operations and Servo Centering
00:25 Preview of Upcoming Steps
00:27 Sensor Setup Overview
00:33 Left Edge Sensor Configuration
00:43 Interface Demonstration Without Actuator

## Transcript

now in the following we will look at how to set up the contourer for guiding or actuation the operator can use that uh home screen to put the web guide in Auto put it in manual and also be able to manually jog it left and right and then also do any Servo centering operation or things like that that's what we're going to see next so I do have a couple of things set up here so I have one sensor that is set up to look at the left edge of the web that shown here since the one is connected and it's set up to look at the net edge of the web and in this particular case I don't have an actuator connected but I can still show most of the items there to that interface

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# SCU6x Controller Web Detect and Web Break Detection and Actuator Response

URL: https://r2r.tech/videos/scu6x-controller-web-detect-and-web-break-detection-and-actuator-response.md

In this video, we introduce and explain the automatic web detect signal feature of the SCU6x Controller. This functionality ensures that the actuator stops moving when the web breaks, even in automatic mode. The video illustrates how the actuator guides the web back and forth and demonstrates the lock on lost edge feature, which holds the actuator's position if no web is detected. This feature is crucial for preventing disruptions in operations when re-threading the web. Join us as we dive deep into how this innovative feature works and its benefits for maintaining smooth operations.

00:00 Introduction to Automatic Web Detect Signal
00:23 Illustration of Web Guiding and Actuator Position
00:37 Lock on Lost Edge Functionality
00:56 Web Break Detection and Actuator Response

## Transcript

so one other feature that we have is that we have an automatic web detect signal in a previous video we talked about this which is that web detect signal we can use that information to stop the actuator for movie even while it's in automatic mode if the we breaks so just illustrate that I'm going to show that and stting the web Maring toward and you can see that actuator position but if the web breaks and there's no web in front of it then the actuator stay stays put and this is what we call as lock on Lost Edge essentially a functionality that ensures that the actuator doesn't get cocked to one side or the other if there is no web in the field of view of the centor and as soon as the web comes back it's going to start dating it when there is a web break it's going to start and hold it position and this is essentially for detecting the uh web Brak and then making sure to stop the actuator in its current position so that it doesn't disrup the the operation once the direct web is started back in

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# SCU6x Controller Web Guide Auto Manual Button

URL: https://r2r.tech/videos/scu6x-controller-web-guide-auto-manual-button.md

Understanding Manual and Automatic Modes on the SCU6x Controller

In this episode, we explore the functionalities of the SCU6x Controller, focusing on switching between manual and automatic modes. Highlighting the indicators—red for manual mode and green for automatic mode—the video demonstrates how the controller interacts with the web, showcasing its ability to detect oscillations. Additionally, the video covers the jog left, jog right, and servo sector features, providing a comprehensive understanding of the SCU6x Controller's operations.

00:00 Introduction to Auto and Manual Modes
00:05 Switching Between Modes
00:15 Web Oscillation Demonstration
00:24 Jog Controls and Servo Sector

## Transcript

this one is basically Auto or manual when it's in red it's in manual mode and if we press it and if it changes to Green it's in automatic mode and [music] um as you can see it's seeing the web right there when I move the web you can see that the web is oscillating here and uh these are jog left and Jog right and then [music] the Sol Center

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# SCU6x Controller: Guide Point Reset Feature Explained

URL: https://r2r.tech/videos/scu6x-controller-guide-point-reset-feature-explained.md

In this video, we dive into the SCU6x Controller's guide point reset feature. This functionality allows operators to switch web widths seamlessly without having to physically move the sensor. Traditionally, changing web widths involved manually adjusting narrowband sensors, but the SCU6x Controller offers a digital solution. We demonstrate the process of resetting the guide point through the controller's home screen, showing how an operator can set a new reference point with just a button press. The guide point offset is also explained, providing precise control down to millimeters. Watch as we walk through utilizing this feature for efficient and accurate sensor adjustments.

00:00 Introduction to Reset Guide Point
00:16 Traditional Sensor Adjustment Challenges
00:50 Digital Guide Point Adjustment
01:34 Demonstration of Guide Point Reset
01:43 Guide Point Offset Explanation
02:26 Final Demonstration and Conclusion

## Transcript

one other key feature that we have is what we call as reset K Co this enables our operators to switch from one width to another width without moving the sensor itself in a traditional application where you have a narrow band sensor that say it's about 6 mm that's looking at one edge of the web if you change from one web width to another web width then what they have to do is they have to physically move the sensor that's like having a rail and move it there and the other thing that they do is that they might have to do a they they might have a micrometer or a fine adjustment to move that sensor just a little bit based on what the guide point is all of these things could be done digitally from our home screen and that's what I'm going to show show you next to show the gide point adjustment uh I have one sensor connected to the controller and enabled and it's set to the left sensor configuration so you can see that when the web moves here it's the left sensor configuration now what we want to do is we want to change the guide point let's say we are running a different job at a different location instead of moving the sensor we want to change the GU point so let for example this is the web and we have traded the web and this is the correct location or this is the ideal location where we want the new reference to be or the game plate to be all that the operator needs to do to reset to this grap point is to press that button and accept and that will change the G point so the G Point offset on this whole screen is showing us how far away from the middle is the current gate point and right now it's exactly in the middle of the sensor speed the you and that's why zero and Visually it's also indicated by this bar right here and this is exactly in the middle of the field of view of that now if we go to the left of the gate point and let's say this is our new reference and the operators instead of moving the sensor they can move the gate point so all that they need to do is press the reset gate point and say accept now we can see that the gate Point number moved there and also this big Point bar with there you know so that one more time let's say they want to use this current web position as the reference then press reset take point and accept and it moves there so this number right here the G Point offset what is showing is that what is the offset from the middle and in that is indicated in MIM so that's to reset the gate point

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# Sensor for center and edge guiding from Roll-2-Roll Technologies 

URL: https://r2r.tech/videos/sensor-center-and-edge-guiding-roll-2-roll-technologies.md

One of the many features of our wide width sensors is the ability to function as a sensor for both edge and center guiding without the need for calibration. See how easy it is to use one sensor for both center and edge web guiding applications in this demonstration of switching from edge guiding to center guiding on-the-fly.

## Transcript

Today we want to show you another of the features of our sensors In this case, we have a 221 mm sensor, we can use for center guiding and at the same time for edge guiding, you just by flipping on off switch. Right now We have it set on a 15 inch guide. And it right now set up and run, as a center guide. However so what I'm going to do now we don't recommend you do it on your machine but just to show you how easy it is to just switch the one from center guiding to edge guiding.

So right now as you can see its set on center guiding. Now, I'm going to put the web guide out of automatic to manual and then I'm going to slide the sensor all the way for the position where it's going to be edge guiding on the same position that we have it right and then I'm going to turn it back on and and do edge and find sensor, and I'm going to turn it back on. You can see the maintain same position It's doing exactly edge guiding in the same position.

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# Setting the Parameters of SCU5 for Servo Center Operation using a Physical or Electronic Position.

URL: https://r2r.tech/videos/setting-parameters-scu5-servo-center-operation-using-physical-or-electronic-position.md

How to set the servo center position or the home position using the SCU5 controller.



- 1: 22 Physically installating a proximity sensor to detect the home position.
- 4:32 Changing the polarity of the servo center sensor.
- 5:39 Some common problems with servo center or proximity sensor installation.
- 7:00 Servo center position based on the electronic actuator position.
- 8:30 Setting the servo center position electronically.

## Transcript

hello everyone today in this video we're going to discuss how we can use our upgrade kit actuator and specifically how do we set the servo Center position Servo Center is basically a term that an industry term that is intended to mean the center of the servo or the hydraulic cylinder but over times it it has changed but essentially what it means is that if you have a web guide mechanism and you want to thread up the web on the mechanism and is there a quick way for us to set the actuator to a position that would make sure that the web guide is parallel to all the other rollers in the machine and historically it's been called the servo Center position you can also call that a home position or whatever you want to call it but the ideal thing is that if the web guide let's say you stop the machine the web guide is to one position and you want to quickly bring that web guide to a home position or a center position and that's what is called as a Servo centering in our system or in our upgrade kits we do provide a couple of ways in which we can achieve that functionality one of the things one of the ways in which we achieve that is by actually physically installing a sensor we call it a Servo Center sensor to detect the home position in this actuator that we have um you can see that there is a sensor that is installed this is basically an inducto proximity sensor it's trying to look for this Race Rod when this Race Rod moves back and forth you can see that the servo Center there's a light on that switch there's a light right here and that light will actually go off or on in this upgrade kit actuator the servo Center functionality is enabled by using the serval Center sensor all that the sensor is doing is trying to locate this Race Rod and the transition from seeing the racer rod and not seeing the Race Rod is basically the home position so just to illustrate that I'm going to move this actuator and you can see that there is a LED kind of thing that lights up and if I move it out and that turns off and that is essentially the servo Center position when you install this upgrade kit on your web guide mechanism what you can do is you can actually Center the web guide manually by jogging left hand so you can jog it left and right wherever you want it to and then the position where the frame is parallel to the rest of the rollers in your machine once you've figured that out then you can actually move this mechanically move it to the location where you think that Servo Center where that transition is going to happen and that that would be the easiest way to set the server sensor okay so just to show that the servo Center functionality we're going to show what happens when we hit the servo center button on the scu5 controller so if I go back to my controller and let's say I have jogged the web guide now you can also see the actuator position on the top right and if I hit the servo center button it's going to go until it sees that proximity switch and the light turns on so if I'm coming from the direction where it doesn't the light is off it's going to go until the light turns back on and if I do the opposite let's say I go in this position where the light is on and then I hit the servo center button it's going to go until the light turns off and then it's going to start turns off and then it's going to stop there so that's how you install the servo Center on our actuator in terms of how what the location is based on the centering there are some situations where you might not have the ability to install the sensor we do have a we do provide an additional option where we can change the polarity of the servo Center so this can be done for one of two reasons the proximity sensor that we have right now it's an npn PN normally open and then let's say you bought an npn normally closed then you can just change the polarity on the servo Center and it'll still work and the other thing is that instead of looking at the the actuator position from the back if you want to look at the actuator position from the front then you can also switch the polarity the way to switch the polarity of the servo Center is going to be tools and then the power user on the bottom and then to the actuator and then there's the servo Center polarity now if I change the polarity it's going to work the opposite way so you can change the polarity I'm not going to show that but anytime you install the will Center sensor on the front let's say then the polarity of the actuator the polarity of the servo Center needs to be changed and that's essentially how you would change the polarity one of the common things that happens or common issues is that it's possible okay one of the things that happens is that our proximity sensor is not installed properly and that when the Target or the Race Rod moves back and forth the proximity sensor doesn't light up so I've just simulated that condition right now and just if we take a closer look at the actuator and when I move the actuator back and forth the light never turns on and it's possible that the operators are not aware of this situation and in that case if they actually press the the servo center button where the proximity sensor is not installed properly this is what would happen so if I press that button it's going to try to go to a certain limit and then it would come back and stop hopefully it never hit the mechanical but what it did is that it tried to look for the transition the transition never occurred so it manually turned off the servo Center functionality with the proximity switch and then it went to what it thought was the home position so in this case the only way that we figure out that this has happened is if you go into the controller and power user and then the controller icon if you notice that the servo Center functionality has actually been turned off what it means is that we are turning off the proximity switch based Servo Center functionality we're not using the proximity switch anymore to figure out where the servo Center is where purely basing the center position based on the electronic of the actuator just to show you what that means if I go back to the home screen you can see that the actuator position is exactly in the middle right there now if I jog the actuator back and forth and if I hit the servo Center it will still come back to this position but this is not the position with the proximity sensor obviously the proximity sensor is not lit up so we know that it's not based on that it's based on the digital position of the actuator again the proximity sensor is there for definitely knowing where the center position is and especially with stepper Motors there are situations in which let's say the actuator is not sized properly then the motor position that we are keeping track of may not be the actual position of the actuator that's why it's always recommended to have the center not just an electronic Servo Center but in the situation where you have the electronic Servo Center I'll go in and say how do you set the center of that position this is the center position right now and the actuator you can see it's at a certain position what I'm going to do is I'm just going to manually jog it to a position let's say I've reached this extreme position and just to illustrate that this is actually working what I will do is I'm going to reset this position as the new Servo Center position and this can be done by going into the motor icon and then if we press the reset Servo Center and press accept now we are electronically teaching the controller that this position is the new center position just to check let's jog it back and then hit the servo Center icon now it comes back to this electronic Servo Center position again the distinction between the electronic and the mechanical is electronic is based on the motor position that we think what the motor position is and then the the call Servo Center functionality is based on a hard switch like a proximity switch that is installed on the actuator or the web guide mechanism we would always recommend using the physical switch but in case something happens then you still have this electronic server Center functionality again if you want to change it the easiest way to change it would be you change the server center with the electronic limit is to go to this screen and then you can manually jog it to whatever location you want let's say this is the location that makes the web guide frame parallel to the rest of the machine hit the server center button accept and now this is the new position and then when I jog and then hit the servo Center it'll come back to that position that's essentially how we can set the servo Center position without a proximity sensor a physical proximity sensor this concludes our video about the servo Center functionality how you can set the server Center physically using a proximity switch how you can set the servo Center electronically without a proximity switch and also talked about the safety feature in case that the center functionality is enabled but the proximity sensor doesn't get triggered then we automatically go into this safety where we turn off the server Center functionality we also saw that and that's essentially it there's also one fine tuning that we could do let's say I move back this Servo Center so that now it's lighting up yeah now it's like lit up and in the situation where you have already installed the sensor but you installed it at the wrong location so it's in this position you had installed it in the wrong location and you want to correct for that there's a way for there's a way where in which we can do that so the way to do that is to go back back into our controller screen hit the tools icon hit the power user controller make sure that the server Center functionality is now it's on now I'm going to actually do the servo center operation and it stops there this position is not the right position mechanically so we want to manually jog the actuator to the new position so we're going to go into this screen I'm going to manually jog the actuator to this position and then just like what we did for the electronic we're going to hit this row Center the middle arrow and accept and then just to illustrate that it's actually doing what we want it to do I'm going to put that right there just as a reference yep and now I'm going to jog and then hit the servo Center all of this happened really quick but what happened was it kept moving until it hit the proximity switch once it hit the proximity switch it moved to the offset position so just to show that again and just to illustrate it maybe I can change this lower the speed okay I'm going to move that hit that it's going to hit the mechanical limit and then it went to the offset now if I go this way it's more illustrative so it's going to go to the proximity switch limit and then it went to the offset it took two steps to go there so that's a way in which we can add an electronic offset even with a physical proximity so this concludes our video about setting up the server center operation please follow us and subscribe to our Channel and look for more videos about how to use our system for your application thank you

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# Simple Guide Point Adjustment for Web Guiding System

URL: https://r2r.tech/videos/simple-guide-point-adjustment-web-guiding-system.md

An upgraded, intuitive guide point adjustment option to make it easier than ever to move the guide point without ever touching the sensor. This option to adjust the guide point is simple and intuitive.

## Transcript

one of our features and our sensor and controllers setups that we have is the automatic guide point adjustment which makes it easier to set up your converting line by just putting the material on your sensor and then once you have the material at the position you want you can just by pressing a button reset the guide point whatever you want so let me show you how it works in this case we have it set up for senator guiding right and as you can see as I move the material around you can see where the material position is at and you can see the center of the material with that green line but however on the top part of the screen or that bar you can see a gray bar that is our actual guide point right now but if I want to reset it to say this position right here all I have to do is just press the reset guide point button and then as soon as I hit accept it will automatically take it to that position so now I have reset my guide point for this operation now this can be used for edge Center guiding with one or two sensors or contrast guiding this is beneficial for people who have operations where they move the material quite often where in in their converting line and therefore do not want to have the hassle of just doing a precise reset of their guide point it's a very easy setup very easy operation and it will save a lot of time for you in your converting line you

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# Simple, quick and easy installation of compact web guiding system

URL: https://r2r.tech/videos/simple-quick-and-easy-installation-compact-web-guiding-system.md

This video shows how easy it is to install the Roll-2-Roll Technologies Compact Web Guiding System. The complete installation and commissioning can be done within seven minutes.

## Transcript

In this video we show how quick and easy it is to install an ARIS Web Guiding System. Unpack the box and lay down all the components such as the cables, web guide mechanism, the web position sensor and power supply. The compact web guiding system is pre-wired for easy installation. All that is required is a single allen wrench tool to fasten the web guide to your machine frame using the mounting holes at the bottom of the web guide.

We even provide the 6 millimeter mounting screws with spacers to make it really quick and easy for you. Carefully unscrew the four mounting screws and spacers from the web guide. Place the four spacers over the pre-drilled mounting plate on your machine. Carefully set the web guide over the spacers paying attention to the direction of travel of the web.

Use an allen wrench to securely mount the web guide onto your machine frame. The compact and lightweight design of our web guiding system makes it easier for quick installation on your machine. The mounting holes also provide the necessary electrical grounding of the web guiding system if the machine frame is properly grounded. Please refer to our user manual for more information about grounding.

Next mount the web position sensor on the aluminum rails already mounted on the web guide. Use the thumbscrews to secure the sensor to a desired position. Using the 12 pin DIN connector on the sensor cable, connect the sensor to the web guiding system Make sure to thread the sensor connector all the way through to secure it in place. Next connect the power to the web guiding system using a pre configured power supply.

Once the web guide powers ON set it to automatic control and the web guide is ready for operation. NO other setup or calibration is required. The intelligent control system takes care of the rest of the settings for the sensor and the controller. We have spent the time on R&D so that you save every minute of your valuable time.

That’s how quick and easy it is to install our guide. All in less than 7 minutes. For more information please contact us.

---

# Single Edge Web Guiding Essentials

URL: https://r2r.tech/videos/single-edge-web-guiding-essentials.md

This episode is part of the ‘Web Guiding Applications and Advanced Web Guiding Concepts’ series and focuses on advanced edge guiding techniques, specifically single edge web guiding. The video explains the use of web guides and edge sensors for feedback in guiding mechanisms. It covers the positioning of sensors, the importance of alignment, and the common practice of repositioning sensors during web width changes. The episode also addresses potential operator errors and their impact on web guiding performance during product changeovers.

00:00 Introduction to Edge Guiding
00:08 Web Guide Mechanism and Sensor Positioning
01:06 Challenges with Web Width Changes
01:47 Sensor Repositioning and Operator Errors
00:00 Conclusion

## Transcript

So in terms of edge guiding, most of you are familiar with this. We have a web guide and an edge sensor to provide feedback for the web guide mechanism. Last month we talked about the guiding principles and fundamentals of it. But essentially in most machines in edgeguiding kind of an application you position the sensor either on the operator side or on the drive side drive or the gear side and then the web is guided to the middle of the sensor position and the sensor is positioned along the cross machine direction so that the alignment provides the required justification of the web.

The main thing with this kind of a system is that it works well for most cases and for maybe majority of the applications there's no issue with it. The main issue comes when we have to change the web width. Whenever there is a product change over and you do a web width change the sensor has to be repositioned. As we get narrower, the sensor has to be moved to a different location.

That location of the sensor has to be justified based on the process requirement. In these examples, the sensors were moved so that the web center line position is always the same irrespective of the web width. But in certain other applications, it may be necessary to justify along the operator side or maybe along the drive side. So that is the only thing someone has to do in terms of product change over is to move the sensor.

But moving the sensor creates opportunities for operator errors and this can have other consequences with the web guiding performance.

---

# Sinusoidal disturbance rejection demo featuring Roll-2-Roll Technologies web guiding system

URL: https://r2r.tech/videos/sinusoidal-disturbance-rejection-demo-featuring-roll-2-roll-technologies-web-guiding-system.md

Roll-2-Roll Technologies web guiding system uses a revolutionary fiber optic web sensing technology to accurately measure web position. In this video, several speeds and several disturbance frequencies are introduced to evaluate the performance of the web guide for a sinusoidal disturbance commonly seen in web lines.

## Transcript

ARIS is an intelligent guiding system that uses a revolutionary fiber optic sensing technology to accurately measure web position. In this video, we use a two guide test machine to introduce several speeds and disturbance frequencies. One machine creates the disturbance, while one corrects this disturbance This test lets us evaluate how our machine adjusts to these disturbances. Watch the red laser to difference between when the controller is off vs when it’s on.

We have a white paper on our website that gives more information about the performance of our guide systems. For more information, please click on the link below in our description.

---

# Steering Guide Installation Guidelines

URL: https://r2r.tech/videos/steering-guide-installation-guidelines.md

In this episode of our webinar series on web guiding fundamentals, we explore the installation and operational intricacies of a steering guide. We cover the mechanics of a single roller installed on angled raceways, its bending action, and essential guidelines for entry and exit spans. We discuss the importance of maintaining a 90-degree exit span angle to minimize stress and prevent issues such as wrinkles and web tear. The video also explains the concept of the Instant Center and its role in web guide dynamics, providing installation tips to prevent oversteering and under steering. Join us to learn about maintaining optimal performance and reducing stress in your web handling system.

00:00 Introduction to Steering Guide
00:05 Understanding the Roller Mechanism
00:22 Bending and Displacement in Web Guides
00:41 Installation Guidelines and Stress Management
01:08 Entry and Exit Span Considerations
01:51 The Concept of Instant Center
02:37 Avoiding Common Issues
03:10 Final Installation Tips

## Transcript

[Music] The second choice for us would be a steering guide. In terms of how it works, it's a little bit different. You got a single roller. This is the top view and this is the side view.

This roller is installed on two raceways at an angle. The web guide forms an arc like that. It moves and forms an arc back and forth. That's how we are changing the axis of rotation.

In this web guide, we are creating a bending. So there is a bending action here. It's displacing as well as bending. In terms of the entry and the exit span, there are some guidelines for that as well and we'll go through that.

This is not an ideal choice for us because it's bending. So it's introducing stress. If it's not installed properly, it can cause wrinkles, creasing, web tear, and edge stresses. In terms of installation, what do we need to look for?

We need to make sure that the exit span is perpendicular to the plane of motion of the web guide. The main thing is to make sure that the exit span is in pure twist. This allows us to have the least amount of stress in the web. So we want to do that.

Now the entry and exit span length is also depending upon the stiffness of the web. You typically need a longer entry span for a rewind guide because the motion of the web guide or the displacement of the web happens because of bending. So you have to follow those guidelines in terms of if you have a stiffer web, you need to have a longer span so that you can allow the bending to happen. Normally it's about 1 to five times the width of the web.

And then the exit span can be half a web width. And there's also minimum formula for finding out the minimum span length. In terms of other things here, let me talk a little bit about the instance center. Like I mentioned, there is a raceway, two raceways here, and they are angled so that you can have the web guide go around an arc.

And the center of the arc is called the instant center. This is important. We need to make sure that the instant center is within this span. and it's at a certain distance about half the length of the span or up to 2/3 the length of the span.

These are all numbers coming from the dynamic model of the web guide and the dynamics of the web itself. If you don't follow those conditions, then you can have a web guide over steering, under steering, creating an awful lot of stresses, maybe wrinkles, slack edges, tight edges and all those kind of things. The main things that we want to look for is this angle. Make sure that it's 90° and then you have an entry span that is pretty long.

You can have different wrap here. We don't want to go more than 45° on either side. When you do that, you're adding twisting. Uh so whenever it goes away from this 90°, it's not pure bending.

There is bending and twisting in mold there. And then we want to have an angle here because when you put bending stresses here, you have the possibility of what we call as moment transfer. So the motion of this roller can actually move the web upstream of the guide roller. In order to avoid that, we want to have certain conditions here.

And we also want this span shorter so that it becomes harder for that moment transfer to occur. Those are some of the guidelines for installation of a steering guide and again sensor as close as possible. [Music]

---

# Steering Guides Installation Mistakes and Options

URL: https://r2r.tech/videos/steering-guides-installation-mistakes-and-options.md

In this episode of the webinar series on web guiding fundamentals, we delve into the critical aspects of steering guides. Learn why it's crucial to maintain a 90-degree angle on the plane of motion to avoid twisting and bending in the web span. Discover the ideal range for raceway angles and the importance of considering web stiffness and entry span length during installation. Proper installation processes are key to minimizing errors and avoiding the common pitfalls that can lead to increased costs and amplified inaccuracies. Stay tuned for essential design considerations and practical tips to ensure optimal performance of your steering guides.

00:00 Introduction: What Not to Do
00:09 Understanding the Plane of Motion
01:05 Wrap Angles and Design Considerations
01:37 Installation Challenges
02:15 Advantages and Cost Considerations
02:26 Potential Issues and Amplification of Errors
 

## Transcript

[Music] Now, what not to do? Same thing. We don't want to put the sensor too far away. One of the things that is not really evident is that we don't want to put the plane of motion of the web guide at anything other than 90°.

It's not this angle between the entry and the exit span that needs to be 90°. It's actually the angle of the plane of motion of the web guide and the exit roller. That's what determines whether you're going to have a twisting action or not. When you have something like that, you're going to introduce bending in the span.

And when you start bending a short span, it's not a good sign. So, we don't really want to do that. So, that's the main reason why we need to have the plane of motion perpendicular. Not really the entry and the exit span, but the plane of motion.

And then like I mentioned, if you have the entry span and the pre-entry span longer than the entry span, then you could have moment transfer happening. That's something that you don't want to do either. In terms of wrap angles, pretty simple. You can have something going up like that or going down like that.

As long as we follow this condition, that exit span is perpendicular to the plane motion, then we are in good shape. Just to summarize the design consideration, design correction is one of the main things there. And the raceways that we have on the steering guides, we don't want to angle them more than 25°. So anywhere between 5 to 20° would be the ideal one.

In terms of installation, steering guide is a lot more complicated to install. You have to consider the stiffness of the web, the entry span length. You need to make sure that you're not putting too much bending stress on the web based on how stiff your web is, the location of the instance center, which depends upon the raceway angle, depends upon the length of the entry span. So, there are lots of things to consider for proper installation of a steering guide.

These web guides are prone to have a lot of issues because they're not properly installed. In terms of advantages, they're they're simple, so they're cost effective. It's just a single roller. So, it's inexpensive, but it comes with other things that increase the overall cost of ownership.

It's hard to install. A lot of attention to detail is required, especially because of the bending and things like that. Loss of traction or anything like a moment transfer occurring can actually amplify the error. So, a poorly installed or poorly designed steering guide can actually produce error, more amplify the error than than what it's intended to do.

[Music]

---

# Stop Missing Splices: Automated Detection for Converting Lines | 1DC Sensor

URL: https://r2r.tech/videos/stop-missing-splices-automated-detection-converting-lines-1dc-sensor.md

Roll-2-Roll Technologies introduces their sophisticated splice detection system using the 1DC480 sensor. Demonstrating at speeds up to 1000 feet per minute, the video showcases the sensor’s capability to detect various splice types, including bright, dark, and transparent splices, alongside voids and defects. The sensor's versatility is highlighted as it differentiates between splices and web instability without the need for reconfiguration. Ideal for customers in the converting industry, this video underscores the efficiency and reliability of Roll-2-Roll's cutting-edge technology in web handling and monitoring.

00:00 Introduction to Splice Detection System
00:13 Demonstrating Splice Detection
01:34 Handling Different Types of Splices
02:25 Advanced Detection Capabilities
04:34 Versatility and Performance at High Speeds
11:29 Conclusion and Further Information

## Transcript

Hello everyone, Arvvin Shadri from Roll for Roll Technologies. Today we're going to show a little bit about our splice detection system. Right now we have the 1DC sensor set up so that it can detect a splice. We just [music] saw a thing splice go through.

Whenever the splice is detected, we have a stack light and the output from the 1DC sensor is triggering a stack light. Apart from a splice, we can also detect voids or defects. You saw a big hole go through and a couple of labels go through right [music] now. So essentially, we can look at some surface defects by looking at the image we are getting from our 1DC sensor.

There's another hole coming through or tear was able to detect that. We have some [music] web instability like you see there. a little bit of a standing wave of wrinkles going through, but that is not being triggered. The sensor is able to distinguish between a splice and some web [music] instability and not trigger for that web instability.

At this point, we're running at about 200 ft per minute just to give you an idea of how the system [music] works and also for you to actually see the splice as it goes through. What we are going to do a little bit later is that [music] the same set of splices. We're going to run it at a much higher speed and see how that works. We do have different types of [music] splices.

Essentially, there's no setup. There's one condition it has been running on [music] and it can detect a hole, a bright splice, a dark splice, a transparent splice, and even a butt splice. So, we do have a transparent splice that is going to come up here. I'll point out when it comes up, but doesn't matter what it is.

Unlike other splice detection systems, we are able to detect all of these different types of splices without making any changes to our controller or the sensor configuration. our 1DC sensor which is 1DC 480 which has [music] about 7,600 pixels and all of this is running at about 200 [music] times a second. So even a bud slice or a really difficult to detect transparent splice, we're able to see [music] that. And sometimes it might be a high contrast splice like a pink material that we are seeing right here and we were able to see that.

The main challenge with splices is that the splices can have different colors. It can vary in the contrast difference between the material and the splice itself. And sometimes it's a hidden splice. That's what we're [music] going to see next.

We have a bud splice where we we have a double-sided tape that is going through right here. It came through. And [music] you have uh two layers of material on top of a double-sided tape. So, you don't even see the tape.

You see the material. It was able to pick that up. And just to give you an indication about different colors, we have a dark color splice coming through and it still picks it up. The other common thing that we get asked about is that how long of a splice tape can we detect?

So, for example, right now we're going to have a shorter tape, a darker shorter tape [music] that comes through. It's able to detect that. That's about a 1 in tape going at 200 ft per minute. We can also detect darker colors or tapes.

As long as there is a contrast difference between the material and the tape, we'll be able to detect that. That's what we want [music] to showcase. Here we have a darker tape coming through. As you can see, it can detect that, too.

Sometimes the [music] splice may not be on the right side. In this demonstration, we're going to show that as well. And obviously, a smaller splice tape, can we detect it? We'll look at tapes coming on different sides of the material and can we still detect that or not?

Another darker one came through. [music] We're able to detect that. While we run this, this is at a slower speed so that the user can actually [music] see the splice. Once this is done, we're going to run it at a much higher speed.

So, this particular sensor, ODC 480, like I mentioned, it's running at 200 hertz or 200 times a second. So, it's able to capture the image, process the image, and send an output within 4 milliseconds. If we have a smaller viewing area, it can run faster up to about thousand hertz of [music] processing speed with these sensors. We are taking that input, processing it [music] and sending an output through EtherCAT.

In this case, this output is connected to our PLC and then the [music] PLC is actually triggering the flag. Now, here's an example where the splice is not on the right side. If you caught it, you can see that the splice was on the other side of where that camera was looking at. Just to give you an example again, another one where the splice was on the other side and we're able to detect that as well.

There is a little bit of splice tape that was folded over and we're still able to pick that up even though the splice is not on the right side of it. just to highlight the versatility of our sensing system in order to be able to detect the different types of splices, different variations in contrast, the way that an operator would do that. Now, another transparent kind of splice coming through. Here we have a transparent tape that [music] is splicing together the material.

And as you saw, it was still able to pick it up and do it. Another one where the splice is on the wrong side. We're still able to pick it up. We can't guarantee that it'll pick up all the time, but most of the time we can still pick it up.

And that's what we are trying to demonstrate here. Another example of a splice. It's a transparent tape and then splice on different spaces. We're able to do all of these.

So, this is just an example of how our splice detection works. In the following, we will speed it up and run it at thousand feet per minute. So you can see how it's able to perform even at higher speed as long as we're able to see it. Again, another transparent splice coming through.

And we can also detect some holes as we saw before. We're able to see some holes and tears and essentially void detection and anomaly detection. All of these things we'll be able to do. So, let's now look at [music] it at a higher speed and see how it does.

Now, we ramped up,000 [music] ft per minute. Some 1 in gray tape went through. A 1in spring tape went through. A 2-in gray tape went through.

A 1-in gray tape went through a dark green splice, a budge slice, a pink tape, a transparent one. Now we are at the end of the roll, so we're going to slow down and then reverse direction again. And there was a label that went through and then a hole or a tear label went through. And then another pink tape.

Now the machine is going to pause and then it's going to go in the reverse direction. And we'll see the same thing in the other direction as well. Heat. Heat.

Here you go. all these places at full speed. So we were ramping up from anywhere from 500 feet per minute to 750 and the max speed was about,000 ft per minute, we were able to catch all the slices, [music] even the butt slice at 1,000 ft per minute. The main thing is that even if the contrast [music] difference between the material and the splice is low, this algorithm that we have for splice detection is able to catch that.

And best of all, you can use this not only for detecting splices but also tears in the web, holes in the web, voids in the web. And we'll have more videos talking in detail about this. Once again, Arvin Sashadri from Roll to Roll Technologies. Take a look at our 1DC sensor [music] for more information about how you can use it not only for edge detection, width measurement, but also defect detection like splice, void, stairs, and the foreign matter on the material.

Make sure to subscribe and enable the notification. Thank you.

---

# Thread counting and monitoring applications with Web Position Sensor

URL: https://r2r.tech/videos/thread-counting-and-monitoring-applications-web-position-sensor.md

Check out the latest edition to our product line. The ARIS WPS 440 can do many things, but in this video we show the thread counting and monitoring applications.

## Transcript

Hello, this is Pedro Velasco with Roll-2-Roll Technologies. Today we're going to talk a little bit about one of our sensors in our web positioning sensor line. So imagine this, what if you have a line where you're trying to run several strands like wires and material so you want to monitor if the wires are there or not. In this case the WPS 440 can actually give you that application.

In this case, I have set up right now seven wires that in the production line probably running over the face, separate from the face that would be running across it right. So if I eliminate, even one take it away, you would actually get a signal telling you that it has been removed, it's missing and that would be one of the features of this product one of the applications. At the same time, if these wires come together then it also can tell you that that is happening also tell you that there's a problem in the system. Additionally it can actually give you just measure each one of the wires and give you an average of the measurement of the width of each wire and then at this same time tell you there's a problem with your system so this is one of the features of the WPS 440- 440 millimeter sensor window and included with the SE unit and closed within the housing unit.

It's all available to you through our Roll-2-Roll Technologies. You can see more information about the sensor at www.r2r-tech.com

---

# Types of Web Guides   Web Guiding Fundamentals Webinar

URL: https://r2r.tech/videos/types-web-guides-web-guiding-fundamentals-webinar.md

Understanding Terminal and Intermediate Web Guides

In this video, we delve into the basics of web guides used in roll-to-roll machines. We explore various terminologies and types of web guides, including terminal guides like unwind and rewinds, as well as intermediate guides such as offset pivot guides and steering guides. Key distinctions and common applications in different industries are highlighted, providing a comprehensive overview of these essential components in web handling.

00:00 Introduction to Web Guides
00:07 Types of Terminal Web Guides
00:50 Intermediate Web Guides Overview
00:59 Common Intermediate Web Guides
01:31 Less Common Web Guides
01:43 Fundamental Principles of Web Guides

## Transcript

In terms of location, when you have a web guide that is located at the entry and exit of the machine, they are called terminal web guides. There are lots of names for these and some of the common names are shifting stand, shifting base, shifting side lay or roll positioning stands. If you're in the metals industry, it might be uncoil or recoil. In other industries, it might be called payoff and tension reel.

Specifically, in these presentations, we call them unwind guide is something that is at the uh entry of your roll throughroll machine while a rewind guide is at the winder or the exit of a roll to roll machine. These are some of the terms used for terminal guides. In terms of intermediate guides, these are the web guides used within the process within the machine. There are multiple types of web guides.

The most common one is called an offset pivot guide. Other names for offset pivot guides are displacement guides, positive displacement guide, pivot frame, or table guide. The second most commonly used intermediate web guide is a remotely pivoted guide. That's a technical term term but most commonly it's called as steering guide or a steering roller or a swivel roller.

And then there are other less common web guides like end pivoted guide or center pivoted guide and then even turn bars are all available. We'll take a deeper look at all of these different kinds as we go along. Most of these web guides work on a basic fundamental principle and that is what we call it as normal entry.

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# Understanding Actuators in Web Guiding Systems | Web Guiding Fundamentals

URL: https://r2r.tech/videos/understanding-actuators-web-guiding-systems-web-guiding-fundamentals.md

Explore the essential aspects of actuators in web guiding systems in this episode of our webinar series on Web Guiding Fundamentals. Discover the various types of actuators, including pneumatic, hydraulic, and electromechanical, along with key terminologies such as thrust, correction speed, and backlash. Learn about the significance of actuator sizing, web speed, and the impact of gravitational effects. Ideal for anyone looking to deepen their knowledge on steering guides and actuator functionality in modern web handling systems.

00:00 Introduction to Actuators
00:34 Types of Actuators: Pneumatic and Hydraulic
00:46 Transition to Electromechanical Actuators
01:54 Common Terminologies in Actuators
02:52 Actuator Specifications and Sizing
03:33 Dynamic Response and Line Speed
03:50 Factors in Proper Actuator Sizing
04:34 Conclusion and Final Thoughts

## Transcript

[Music] So in terms of actuators, there are lots of terminology that is involved. Some of them are thrust or power, how fast the accelerator is, what is the correction speed, what is the acceleration, stroke length, mounting, what type of coupling we have and things like that. Actuators are pretty standard right now. It's not as important as installation of a web guide or the sensor, but it is an important part of a web guiding system.

The older actuators were either pneumatic or hydraulic. You had an hydraulic pump pumping a double acting cylinder and moving the web guide structure. These were more common in the 50s and up to about maybe '90s before the electronic electromechanical actuators started coming into the market. You could have pneumatic actuators or hydraulic actuators.

The hydraulic actuators have the advantage that it can provide high thrust and can shift large loads quickly. Even now in metals industry, hydraulic actuators are pretty common. You can see them. But the problems are that it's a problem with maintenance.

You need to balance the valves and stuff like that. Change the filters. They could cause leak and this could contaminate your product. And then the precision and accuracy that you can get with an electronic actuator or electric actuator is not something that you can expect in an hydraulic actuator.

So most web guides nowadays are going to use actuators like what these actuators usually have a motor that drives a belt pulley system. There's usually a lead screw, a ball screw or a roller screw that converts the rotary motion into linear motion at the end of the actuator. Some common terminologies that you would see with actuators are maximum current, voltage, power. Whenever we have something with a lead screw or a pitch, that's a common term.

What is the lead of the actuator? Pitch of the actuator. Gearing ratio. Backlash is another thing that you would commonly see with electric actuators, especially with low-end lead screw actuators.

Resolution. What is the smallest movement an actuator can produce? Back drive is a common terminology especially if you're installing a web guide that has to work against gravity. And then types of actuators you have inline and reverse parallel.

Some actuators have limit switches or end stops. And then type of motor used in the actuator. You would commonly see servo stepper brushed or brushless DC motor. So actuators are providing the driving force to the guide structure so that it can position the web.

In terms of thrust, the thrust is the amount of force exerted by the actuator to move the guide structure. And this thrust really depends upon as we saw before mass of the structure that we are trying to move, what is the friction there, how fast you want to move and sometimes gravity as well if you're acting against gravity. In terms of sizing actuators, these are some of the things you need to know to size an actuator properly. a web blind speed mainly because if you have a slow moving web the maximum disturbance frequency you can get depends upon the speed of transport of the web.

If you're moving at 100 ft per minute you might not need a high dynamic response while if you're moving at high speed you might need a much higher dynamic response. The dynamic response is related to the acceleration. Acceleration is related to the thrust. So that's why line speed becomes important.

Guide structure weight and roll weight. If you're trying to move a big mass, we need to know that what type of bearing you're using. So that what is the breakaway force that we need to overcome based on the coefficient of friction of the bearing and then what kind of disturbances we are trying to correct for. There is a correlation between the amount of disturbance that can propagate through a roll-to-roll machine that really depends upon the speed of the web.

The faster you go, higher frequency disturbances can go through. So the web acts as like a low pass filter and then the acceleration and then if you have to look at any gravitational effects. These are some of the key factors that are involved in properly sizing an actuator. But like I said, actuators are pretty straightforward nowadays.

Just need to have some basic questions answered and then we'll be good to go. [Music]

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# Updated Pneumo-hydraulic Upgrade Kits

URL: https://r2r.tech/videos/updated-pneumo-hydraulic-upgrade-kits.md

Are you looking for an affordable option to replace your pneumohydraulic or electromechanical web guiding systems? If you have an existing web guide with outdated sensors and control unit, then check out this affordable web guiding system upgrade option. This upgrade kit has even better technology and easy to use functions. We now have a solution with our upgrade kits featuring Roll-2-Roll® Web Positioning Sensors and Roll-2-Roll® Control Units for all electromechanical and pneumohydraulic web guide systems providing advanced edge and center guiding.

## Transcript

hi in rolls-royce technologies we keep making advancements with our products and I want to talk to you a little bit about the our retrofit kits for web guiding systems now our retrofit kits are available for most applications that are out in the market the advantage is you just replace controller the actuator and the sensors on your web guiding system and just keep the mechanical components mechanical components can last a very long time and they're easy to maintain but the this part is what's really the the the nitty gritty of a web guiding system and what we want to allow you to do is to have the most advanced technology in your existing web guiding system so for a typical what typical retrofit kit would be composed of a a control unit with a screen a motor driver an actuator and a sensors in this case what I have and what I'm showing you here is something that we have actually modified to our old systems they make them a lot better according to what our customers have been requesting from us for example in our in our motor driver now it's a quick disconnect so as you can see we can just plug and unplug a cable here and allows you to also have the same thing on our actuator now this allows the customer to select the size or the length of the cable that they need and it's on off-the-shelf cable so you don't really have to buy from us you can go directly to the cable suppliers additionally we have also come up in our sensor mountings we have come up with brackets that slide are easy to lock on to position very sturdy so therefore you just mount a aluminum extrusion or one inch aluminum extrusion and it's very simple to use you just turned the the locking mechanism and you can slide it into position water ever you want and once you have it in position you can lock it back up and it's firmly in place now these aluminum extrusions you can buy them off the shelf and you can buy them for any length that you want so these are very very handy to have now they are also available for our other sensor sizes for the 221 millimeter sensor to now the advantage of the 221 millimeter sensor is that with the flow these forty eight millimeter sensors you would have to move them if your web with changes quite a bit but with a 221 if the web width is within the sensing window of the 221 you can just use our application where you can adjust the the guide point either automatically or by just with your finger or by setting it by moving it in increments of a certain length so that's those are some of the features so with our actuator we can provide you with options as to how to connect the actuator to your machine now we can provide you with either clevis amounts on e on either side or we can provide you with a feral rods it all depends on what you have in currently installed in the machine we're trying to get as close as possible to doing this that's a drop in there might be some slight modifications but if we can you make it as a drop in it will be a lot better for you now another thing that we have available for you a controller that has the operator interface and a screen touch screen where the operator can actually do all the controls of jogging left/right or several Center put the machine in operation determine whether what the sensors are the controller also has up to two sensors that it can work with for the guiding process another thing that we have available for you now we have a team of sales reps all over the United States so they can help you start the process of determining what do you need for your system in order to do the retrofit retrofit kit for your current web guiding system in order to do that all you have to do is just go visit us at our website at www.ge.com tacked us there we have a whole listing of all our are all sales reps all over the US in Mexico and in Europe we hope that this can be of service to you and we believe that this application of retrofit kits will be of great value for your operation you

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# Updated Sensor Mounting Bracket

URL: https://r2r.tech/videos/updated-sensor-mounting-bracket.md

New and improved sensor mounting bracket! Our customers wanted a more robust mounting solution, so we're providing a sturdy, easy to use, and affordable sensor mounting. Order yours today!

## Transcript

hello this is Pedro Velasco withdrawal to all technologies we had some customer feedback on our sensor mountings and we did some some research and then we created a new sensor mounting that you can easily put on your operation so for example for 221 sensor as you can see our we have our typical sensor mounting which is as brackets that we ship our sensors with but additionally to that we just found these off the shelf brackets that we can mount on a one inch square bar in this case it's a extrusion and it fits perfectly this so it allows you to with a quick release just to be able to move your sensor around really easy right so you can just light it through and then once you use your quick release and just tighten it back up it provides a very very sound fixture so these has pretty good for those operations what we're doing retrofit kits on new hydraulic systems and people want to have the sensors mounted on the existing bar or they can just acquire a new aluminum extrusion bar or one-inch extrusion bar and they can just mount this now this is off the shelf so it's a very easy to to access and we can provide it for you or we can tell you where you can buy these so that you can do a very sound mounting of our 2:21 sensor on your retrofit kit for replacing pneumo hydraulics so you can see more of this at our website on wwr to our Tec h so it's you

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# Web Guide Actuators

URL: https://r2r.tech/videos/web-guide-actuators.md

Roll-2-Roll Technologies doesn't just cater to the narrow web guide applications. Our line of actuators can help you in both narrow and wide web applications at any point in your converting process that requires accurate and precise positioning of your web.



Electromechanical actuators are used when quick reactions to changes in the web position are needed. The actuator connects directly to the control unit.



Our full range of actuator solutions includes the LHS actuators for narrow and wide web guiding, complete systems or retrofits, and RLA actuators for unwind and rewind systems. The thrust capabilities range from 50 lbs up to 1,500 lbs.

## Transcript

hi this is petrol in law school with roll-to-roll technologies most people think of us as a narrow web company but we actually go into the white web applications - and to show you that we want to present to you our wide range of actuators available for both narrow web applications and white web applications in this front row I have for our narrow web applications these are the actuators that we use in our smaller web guys they go up to about for up to 22 inches in width and so they can handle web's up to 20 inches in this case this a small actuator is what we use it can handle up to 50 pounds of thrust so 450 pound tension applications and it's what we use in our low profile web guides then we have our our larger actuators which we use for applications such as our compact web guide and these can also go up to 50 up to about 150 pounds of tension and then we have the double stack actuator which we use in bigger applications and these can go up to 200 pounds force so they're all available for you for narrow web applications also we have an application for our retrofit kits in this case I have one of our featured actuators which you can see it also has mounted the several Center on it now this is a very robust application it can be provided with you with eyebolt terminals on either side or we can easily with clevis doing so if you have a web guide in your in your plant that requires you know the mechanical parts are all good the controls are update outdated you can actually we can provide you with an actuator and our controls and sensors to it so this is more or less the setup that we will probably we can mount it either through the eye bolts we can mount it through clevis or we can mount it directly on a any fitting that you might have on your machine these are very easy to install and they come already with the several Center mounted on them so it's all up to the particular application that you have in a problem that you want to solve another area that we want to talk to you about is on our terminal web guides like I mentioned before people think of us as a narrow web company but we're not we actually cater up to also the the wide web applications and also we cater to the terminal guy diplucate so in this case we have featured some of our what we call the actuators for terminal guides for online xandrie once we have multiple ways of installing these on your machines depending on your needs we can do either clevis mountings or we can install it directly on the base of the actuator now we can provide you one that would work that would move a 1500 pound load a 5,000 pound load or up to 15,000 pound load so it's a very hefty product as you can see it's a very heavy and we use it to like I mentioned before to move unwinds and rewind so I have it hooked up to our one of our control units with one of our infrared sensors and just to show you how easy it is it can work pretty well with our with our controls right here right and if I put it on automatic as I use my hand as a material you see how it just and we can adjust the speed of this application depending on your needs so we hope this has been of information of use to you and like I mentioned before if you need any help with retrofitting an old web guide you can contact us more information you can go to our website ww2 and thank you for a time you

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# Web Guide Solutions: Retrofit Kit for Pneumo-hydraulic units

URL: https://r2r.tech/videos/web-guide-solutions-retrofit-kit-pneumo-hydraulic-units.md

Looking for a way to update your pneumohydraulic converting machine? Using a retrofit kit from Roll-2-Roll Technologies saves money and hassle without having to replace your entire line. Learn about the many benefits a web guide retrofit kit has to offer. Whether you want to upgrade an existing machine or experience the latest in web guiding technology on a smaller budget, retrofit kits are the answer.

## Transcript

hello this is peridot a last go with roll-to-roll technologies now we have customers that have come to us because they have new more hydraulic units installed on their own their lives now they're using this new hydraulic units to guide the web now there's something a problem with these new hydraulics is that number one there are very bulky piece of equipment so they occupied it a lot of space in your line additionally you have all these hydraulic lines running all over the place at the same time they're very noisy and actually you have the risk of having leakage or any importance to that draw the fluid which can mess up your operation very bad especially your products another issue that we have with those is because the sensors are actually running with air then they have issues issues with the with accuracy and at the same time there's an issue of maintenance you have to change filters every so often and there's the issue of cost these things are very costly to operate because the motor on the hydraulic unit has to be constantly running so we have a solution for that with a retrofit kits for these for these new hydraulic units in your lines so one of the things that we want to show you today is before and after of a retrofit kit that we have done so on we actually took one of these steering guides and we can show we're going to show you how we did the retrofit specifically of the actuator a hydraulic actuator and we put our electromechanical actuator on it and at the same time we can talk to you a little bit about more how the system reduces the space required for this and at the same time how your performance will increase because of our accuracy that we provide you with our system so in here we show you the finished product of our retrofit in this case we have installed our motor actuator on system we replaced the hydraulic unit that they had the hydraulic cylinder they had and we placed a several Center sensor we have we would provide you with a motor driver for this unit this is the plate that we prepare for you so you can adapt this into the your assembly on the Raceway and it would make it very simple to reinstall in your opera so now as we can see we have most of the components of required to do an Omaha Dalek retrofit kit the control box the we have the actuator with it's a motor driver and then we have the sensor itself in this case we have a 221 now the 221 allows you if you have a let's say variations and width of material that you're going to run 221 is actually very good and if you have to 220 once you can do a center guide with it but what I want to show you here most most important is this is how we would actually have it installed on your line so in this case you have the 221 and then on the backside you can see this is would be the bracket that we would use to mount it on a rail that we can make it out of a one-inch extraordinary minim which can go any width that you need that you require and it's a very simple to use bracket it has a brake or a lever that acts as a brake and once you release it you can just slide the sensor easily in position and once you have it in position you can just close it back up so as you can see here are some of the benefits that we provide you when you actually do a retrofit with our electric electrical mechanical system in comparison with the pneuma highway number one is there is no leakage so you have no issues of having hydraulic fluid on your floor or on your product considerably less noise the only thing you might hear if you even hear it is the sound of the actuator moving mm-hm we provide better accuracy because we're using our high-end technology the newest thing that we have on the market which is a sensor that requires no calibration in very high accuracy in comparison to using a sensor that uses air lower power consumption because we're using 24 VDC that's all it is before you are using a motor that requires 220 volts into it so it's a very high wattage that you're gonna have to operate we have less maintenance with this because with a new mahalik system you need to do changes of filters and you need to do checks of couplings in connections so this reduces the cost of operation better control and more flexibility because we can put the operator interface in any place that you require we can actually connect our controls to a PLC and better yet something that in the future is going to be where the web handling industry is going to its data collection for usage in determining the your processor health or any other things that you might want especially with key like issues so we hope that this has been educational for you and will help you make a decision if you have a pneumo hydraulic unit just contact us and we can actually help you with how to do this retrofit in your and your operation believe me you will save a lot of money by doing this this this changeover if you want to find out more about our systems and about other products that we have you can go to our website WWE you

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# Web Guide Upgrade Kits

URL: https://r2r.tech/videos/web-guide-upgrade-kits.md

Do you have an existing web guide with outdated sensors and control unit? We now have a solution with our upgrade kits featuring Roll-2-Roll® Web Positioning Sensors and SCU5 Controller for all electromechanical web guide systems, providing advanced edge, line and center guiding capabilities. 

## Transcript

Roll-To-Roll technologies offers web guide retrofit kits for operations that need to upgrade their guiding systems. The mechanical systems and web guides can outlive the control Sensor and/or the actuator in their guiding systems we can provide options that allow you to retrofit our sensor Sensor control unit and actuator to an existing web guiding system The upgrade is easy to install and you will get the benefits of the technology that powers errors products Making your process easier to control For more information, visit us at www.r2r-tech.com

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# Web Guiding and Monitoring Contrast Sensing - SCU5 Controller Set Up for Contrast Sensing

URL: https://r2r.tech/videos/web-guiding-and-monitoring-contrast-sensing-scu5-controller-set-contrast-sensing.md

Roll-2-Roll Technologies' SCU5 Controller and Sensor system allows converters to use the contrast mode for line guiding in a few steps. This video shows how to teach the controller to tract a specific contrast for web guiding and monitoring. In additional videos we will discuss specific applications for contrast sensing that allow your converting operation to run more efficiently.

 ![SCU5 Controller in contrast teaching mode](https://r2r.tech/sites/default/files/inline-images/SCU5%20Set%20Up%20line%20guiding%20and%20monitoring.jpg)

## Transcript

today we're going to go through the operator sensor screen in order to teach a contrast sensing application when dealing with contrast sensing the operator will have to access the operator sensor screen on the su controller access is achieved by pressing the tool icon on the operator interface screen the next screen will be the advanced settings menu the screen has a keyboard and three icons the return to main screen icon the operator sensor settings icon and the operator power user icon by pressing the operator setting icon this will have access to the operator settings screen in the operator settings screen we press the operator sensor icon pressing this icon gives us access to the operator sensor screen this screens allow the operator to select a sensing mode to select a sensor to teach to adjust for brightness and control to specify the brightness control the thresholding mode and to select the type of contrast sensing that best suits our application verify that the sensor selection button has the correct sensor in this case we have set sensor 1 for this demonstration if we press again we would have sensor 2 but it is not connected so we return to sensor 1 by pressing that icon typically when you're doing a contrast sensing application the sensor should be a white light sensor as shown on the embedded screen view on the upper right next verify that the sensing mode is correct the sensor mode button should show three vertical spaces black green and white if it's black and white it is in edge sensing mode so we must press the icon to change to the contrast mode to teach the contrast sensing mode press the teaching button so it is green the screen will show the different contrast modes available depending on the application required press the sensing mode that best suits the application when you press the sensing mode desired the arrow or arrows pointing to the mode selected will turn green as i show right now next select the feature on the live process image preview which is this bar right on top that is to be detected to select a feature use the feature navigation keys or either side this will allow you to move through the different features and it will highlight the feature with a green outline once this is done where we have selected a feature then we press the teaching button icon and it will turn red therefore locking that feature all the contrast buttons will disappear except for the contrast selected this contrast has been set through the teaching mode we return to the main operator screen by pressing the button the bottom left hand side of the screen until the main operator interface screen appears in other videos we will discuss the specific advantages of our sensor technology for contrast sensing and we will show other contrast sensing features that can be of use to your operation now if you found this video useful like our video and follow us on youtube also you can go to our webpage at r2r.tech and contact us to discuss your own application and receive more technical and application information regarding web guiding and monitoring

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# Web Guiding Applications and Advanced Web Guiding Concepts: May 13th 2020 Webinar

URL: https://r2r.tech/videos/web-guiding-applications-and-advanced-web-guiding-concepts-may-13th-2020-webinar.md

### Web Guiding Applications 



- Edge Guiding  Straight edge
- Fuzzy edge
- Jagged edge
- Wrinkles

  Center Guiding

- One sensor measuring two edges
- Two sensors, one each for an edge
- Moving sensor center guiding (mechanical sensor repositioning)
- Electronic guide point adjustment

  Line guiding

- Contrast/pattern guiding
- Line/contrast/pattern guiding on unwinds and rewinds

  Mechanical chasing application Electronic chasing application Mechanical master/slave application Electronic master/slave application

### Advanced Web Guiding Concepts



- Dead bar
- Dead band
- Actuator stroke limit
- Lock on lost edge
- Loss of contrast/line

## Transcript

and I'll be your presenter today I just want to make sure that I take care of some housekeeping stuff all of you are currently muted and you won't have access to the microphone but you can use the chat window on your left hand side of the screen to send messages to us I'm also here joined by Pedro and Carlo both from both tall technologies and they will be monitoring the chat channels basically the Q&A and you can type in your questions or comments there we will also be having some polls during this presentation just to get an idea about who you are and what kind of function that that you do at your institution so I do have one right now which is asking about what market do you belong to or what industry that you belong to so if you have a chance feel free to answer those poll questions these will be really helpful for us as we go along and I'm gonna wait a little bit more time to give some more people some time to join but we should be starting in about couple of minutes okay let's go ahead and get started so well once again thank you for attending this webinar this is gonna mainly focus on web guiding applications and a few advanced web guiding concepts basically we're going to deal with edge guiding and line guiding we're not going to cover any control concepts in this presentation but more in terms of structurally how do you do edge guiding for different kinds of application so the key concepts that we will be covering in this edge guiding aspect of it is single edge guiding that is guide the web based on just one edge and then what is center guiding and we'll also cover some topics about sensor positioners there are different types of sensor positioners what is a moving sensor centric guiding system some of the later concepts are the current technology is related to what is called as a guide point so we will talk okay so there are some feedback saying that they're not able to hear one second okay so hopefully you guys are able to hear me Joe if you can hear me just say yes okay so the current technology with respect to guiding involves a concept called as guide point we'll talk a little bit about guide point and then we'll also talk a little bit about remote guide point adjustments this is we needed for coordination between different web guides and then we also talked about couple of different concepts called as Deadman and edge filtering so that's kind of a quick overview of what you're going to look at in edge guiding we're also going to look at other things related to line guiding as well as what are some of the issues with both of these techniques okay okay so in terms of edge guiding most of you are familiar with this we have a web guide and an edge sensor is there to provide the feedback for the web guide mechanism last month we talked about the guiding principles and fundamentals of it but essentially in most machines in edge guiding kind of an application you position the sensor either on the operator side or on the drive side drive or the gear side and then the web is guided to the middle of the sense of position and then the sensor is positioned in a location along the cross machine direction so that the alignment provides the required justification of the web so the main thing with this kind of a system is that it works well for most cases and for maybe majority of the applications there's no issue with it the main issue comes in when we have to change the web width whenever there is a product changeover and you do a web with change then the sensor has to be the pre position so as we get narrower and narrower the sensor has to be moved it has to be located in a different location there and that location of the sensor has to be justified based on the process requirement so in these examples the sensors were moved so that the web centerline position is always the same in respect of the web width but in certain other applications it may not be necessary and it may be necessary to justify along the operator side or maybe along the drive side so that is the only thing that someone has to do in terms of whenever they do a product changeover is to move the sensor but moving the sensor creates opportunities for operator errors and this can have other consequences with the web hiding performance now in order to another way of doing the guiding is to have two sensors one on either side of the web this is called as Center guiding and the center guiding is one of the commonly used techniques whenever we need to justify the web to the middle of the design or the middle of the process here in this case the sensor the control system takes the values from the two sensors and the average of those two values will provide the centerline position and then the web will be aligned to the middle of the two sensors that's what happens in and rotating again when we have central kiting we still have the same problem with web with changes and this requires the sensor to be positioned on either edge and here it's a little bit more complicated in the sense that when you move both the sensors both these sensors have to be moved equidistant from the center line position of the machine so again creates opportunities for operator error during changeover and things like that in order to avoid the issues with manual positioning and also to automate the process some kind of mechanism are used to position the sensor these are called as sensor positioners as you can see here this is basically an actuator that drives some kind of a lead screw or a belt or anything like that and then the two sensors are mounted on that linear rail or lead screw mechanism and when the web wit needs to be changed this actuator is driven so that either it retracts or it it goes towards the web or it goes away from the web inside the web or outside the web to move the sensor to the right location now this control can actually be done continuously it doesn't have to happen only when a machine is stopped or when a product changer workers the way it is done if it's done continuously is to actually have another control loop where the two sensors are actually chasing the web one control loop is used to guide the web where it's actually guiding and then the other control loop is used to chase the web so that it can adapt for the web with changes so this is usually referred to as moving sensor Center guide the actuator can be electromechanical or it could also be hydraulic but most commonly it's electromechanical actuators or those that are used right now so as an automatic sensor positioner is used to move the sensors so that the web weight changes are being accommodated by this system now the main issue with sensor positioners or moving sensor center guide is mechanical wear and tear as you can imagine the actuator needs to continuously move back and forth and then that creates a lot of issues it is also complicated just because of the fact that you have two control loops and there are two control gates that someone needs to worry about one is for the guide mechanism and then the other is for the chasing mechanism and then obviously this requires an additional drive or an additional output in actuator for the system and then all of these just makes it complicated there are also issues with it in terms of stability issues if the chasing is too fast and things like that then that are plagued plaguing this kind of our system again when the web word changes the sensors are moved back and forth and this can happen automatically continuously or it can happen during changeovers where the operator press the button to chase the web and then stop the chasing mechanism and continue guiding the web an alternative solution which is getting more popular lately is actually to use two sensors two white sensors that can actually span the entire web with width change when we do something like this where in respect to of the web width you don't have to move the sensor then this kind of a mechanism completely eliminates mechanical moving parts reduces wear and tear on the system and then it will be simple to use there there will be no need for the sensor to be moved and it's easy to maintain and there's only one actuator the only the only one actuator is the actuator or the web guide and hence there's only one loop again the two sensors will provide their own measurements and then the control system will use the average of those two measurements and if the sensors are wide enough so that it can capture the entire width change that is experienced in the process then this would be a really simple system to use it doesn't have to be a single two sensors if the sensor is wide enough it can actually cover the entire viewing entire web surface so that it can look at both the edges of the web again like I said this is one of the most robust and simple kind of a installation where it it reduces operator errors and things like that now one of the things that when we have a wide sensor that comes it comes to us is what is called as a guide point so here we have the sensor window and this might have a sensor range from maybe two inches to maybe thirty seven inches it could be any within that range and the the old sensors we're like mainly like points or sensors and they were just looking for the edge position and it was just looking at just a small variation and as long as you're doing a guiding the sensor range really doesn't matter so we were able to get away with the smaller sensor range but with the advances in sensing technology and things like that now we have the opportunity to look at a wider so with a wider sensor window now we have the opportunity to and not only guide the web to the middle of the window but to any arbitrary position within the window the reference position or where the web guide is controlling the web location that's called the guide point and then the error if the web position falls to the left here it'll be a positive error that the web position foster right here will be a negative error and we can actually electronically move the guide point in such a way that if the web width changes we can actually move the guide point instead of moving the sensor now this is an example where the web with reduced so we moved the guide point and this allows us to instead of manually positioning the sensor we can electronically position the location of the web so by moving the guide point you can actually use a single sensor and you can still do central guiding as long as you know how wide your web is and it's just a matter of mathematics to get it get it there electronic guide point enables us to do quick changeover it doesn't require an operator to move the sensor manually or to the sensor positioner manual movement of the sensor or being avoided right now just because of the safety reasons and things like that we don't want an operator to get into the Machine and move the sensor so there are some lead screws or motorized stages that would move the sensor and then if we know the width of the product based on a product code or something like that then we can pre-program this guide point changes whenever a change of workers and this may said extremely simple and quick to do a changeover now the guide point or the concept of guide point it not only is for a single sensor but it's also for two sensors it's just a matter of us going into the mathematics of it it's just simple algebra that we need to go through but essentially we can even have a guide point for center guiding applications and that guide point would be a function of the relative position of the two sensors and then basically how they are installed with respect to the center of the machine and then the movement of that guide point would be seen at each of these sensors by half the change in the guide point so and with me have two sensors we can we can come up with all different scenarios and and we can also offset the web guide from the central line position based on making some changes to these guide points and like I mentioned if you don't know the width of the material that you're running or the product could have variations in width then if you put two sensors that are equidistant from the middle of the machine irrespective of the web weight change the guide point and may not be changed so there's really no need to change that so for example here when we change the web width from a wider web to a narrower web the width is going to go down equally on either side of the web and since the web guide is already controlling it it's going to make sure that it sees the same amount of wear on either sensor and that helps us to do changeover without even changing the date point and when we use two sensors so mainly center guiding offers us several advantages first and foremost is that it averages the edge position because we are looking at both the left edge and the right edge and that helps us averaging that and when you look at other challenging applications later on you will see that how that's helpful and then you don't need to do any guide point adjustment and then even with a manual or automatic sensor pushing is not necessary it's really simple to install maintain and operate and technically if you have two sensors on either side of the web it is an inherent WebKit X sensor so you don't really need another sensor to say there's a Webber's present or not and then you can also do width monitoring at the same time web guiding and wit monitoring can be done at the same time with this kind of system another concept that is is that I wanted to introduce is what is called as a dead band so now the guide point is the reference position where the actuator will change direction to guide the web you can introduce what we call it as a dead bag and what that what that does is that whenever the web fall falls within this dead band the actuator will not actuate as you can see this Web edge here is kind of like fuzzy and serrated and and it's not that great while here it's like a straight slit edge you don't really want the web guide to be moving back and forth for every small change in the web edge position and in order to avoid that you can is what is called as a deadpan and essentially what it does is it's a region where the error is going to be zero and then this non-linearity here and then the error becomes negative or positive based on the direction so the dead band is usually around the guide point and and it's usually maybe half a thousands or ten thousands five five thousands or ten thousands and you can also adjust the deadband electronically based on your application when you don't have a really nice edge then and you don't really want the web guide to follow those edges all the time you just want a grass positioning of the web you can also filter the edge position typically we use like an exponential moving average kind of a thing so for example here this is data from one sensor as you can see it's kind of like a sinusoidal position here and then this blue line here is the data from the other sensor and the standard deviation is about seven for each of these sensor outputs like I mentioned Center guiding is gonna average out that without any filtering just by Center guiding you are reducing that standard deviation just by taking the average of those two signals but if you go in and actually filter that like using an exponential moving average then you can reduce the standard deviation here so we use what we call it as an exponential moving average edge filter to make sure that we don't react too much to these edge variations and essentially it's like an infinite impulse response filter and and the coefficients of these can be adjusted based on the speed or if you know how much variation you're going to see with the web edge that you can adjust that the faster you go the web itself is filtering those variations for you but it's mostly effective for sinusoidal or randomly kanna distributed edge positions now in terms of some of the challenging applications or aspects of edge guide II will talk about these few items here one by one so first one is like like a fuzzy edge so you have an edge like this which is extremely serrated maybe it's coming out from some kind of an extrusion process or things like that and you really don't care about getting it within five thousands or something like that but more about I want to get it in place because I'm going to do an edge trim here so if you have edge guide control system just regular plain Jane one then you're gonna have issues with oscillation so every time this edge position changes your web guide is going to oscillate back and forth back and forth and then your accuracy of the guiding system is not going to be any better than the edge variation that you see here so one of the things that you can do to handle web like this is to obviously do a central guiding and that will average out the two positions then use a dead man I'm filtering based on your conditions here now there might be some occasions where you have an edge that is deliberately like this it's got like a square wave or a sawtooth wave or some kind of a profile that is deliberate for the product now what happens here in this case is that if you have a conventional sensor that is looking at this edge that profile is going to be like a square wave and and the other thing is that depending upon the the duty cycle of the square wave and depending upon the speed and the sampling rate of the sensor you might be sampling on the high side all the time or you might be sampling on the low side all the time or any combination of those and whenever the speed changes it's going to cause the the web guide to shift or drift based on the speed changes which is a function of the profile of the web that you see here so how do you how do you tackle such a kind of a web now we did temporal filtering that is time based filtering we can also do like space based filtering or spatial filtering and use what what we call as a bang-bang control to do it this is an example where you have this web that is kind of serrated and typically we would install the sensor along the cross machine direction of the web but in this case we wanted to take advantage of the way the sensor measures the edge position and the offset between the sensor so we were able to do what we call a Slyke averaging along the length of the web spatially and then also have a time-based averaging and then do a bang-bang control that means like it's if it goes here move here it goes there move here and there's a dead band there so that's one way of tackling a complicated edge like that now the other common problem that you're going to see what edge guiding is wrinkles now wrinkles in in by nature it's really hard the the type of the wrinkle it could be like shear wrinkle with different shapes and forms and things like that but essentially what it does is that when when the web buckles the troughs that are created are going to reduce the width of the web so if you're just gonna guide based on one edge you might be oscillating back and forth because the wrinkle is gonna cost the edge to come in and come out come in and come out and things like that and most often you should try to eliminate the wrinkle problem before trying to fix it with guiding but if you have to fix it with guiding then obviously center guiding with edge filtering and deadband is something that you should try to use to reduce that issue again first and foremost we need to try to see if we can eliminate the wrinkle problem and then if you still can do that and you still need to have better guiding then you can add these techniques here and do that now I mean finally in terms of material and you're going to come across some porous webs or blow basis waiting on moments with a typical conventional sensor that works based on blocking and unblocking the porosity changes can actually fool the sensor and that might cause a pseudo edge movement when in reality the weather's not moving at all and this might cause guide oscillation when the sensor controller gains are high or like a really sluggish response if the gain is set to low overall like a porous web where the sensor signal goes through then you're going to have issues with guiding now obviously if you have a better sensor then you can do better and if the sensor is not affected by porosity or opacity then you wouldn't have that issue at all but if you don't have that option then you can certainly do filtering and also do deadband if you have a little bit information about your web and the opacity changes so just to give you an idea this is let's say these web edge position from one of the sensors which is in the blue line here a dotted blue line and then the other one from the other sensor when the signal goes through the sensor and when the porosity or the density changes occurs and that would be perceived as a web position change at the sensor now if you do center guiding obviously you can try to eliminate some of those averaged out some of those and then and the the filtered one is shown here in solid line so if you do like a moving average filter then you can further reduce that and try to eliminate a lot of those oscillations in the website because of that now if you add a dead band on top of the moving average that would actually significantly reduce those edge variations or the perceived edge variations because of the opacity changes and you can do something like that so just to give you an idea like if we look at the standard deviation of each of those sensor values you have a standard deviation close to one if you just do with one edge guiding without any filtering additional thing if you just do Center guiding you can significantly reduce that standard deviation now if you apply a moving average filter you can reduce that even further and then a dead band can reduce that even further again these application of moving average and deadband all of those really depends upon what kind of material you have how much information that that you have about what is the expected variation and things like that so those are material related challenges in guiding there are also challenges in terms of coordinating so let's say you have two different layers of web that need to come here and they need to be laminated and this this lamination process the simplest way is to have two standalone web guides that are guiding the web and then somehow physically have the sensors of those corresponding web guides exactly at the correct position with respect to each other and if we do that then we should be able to laminate these two layers of the web but usually this is well sometimes this could be a challenge because if there's web with variation or some changes and things like that where you would require some kind of a coordination between these two web guides so that when this layer comes in in contact with this layer they are aligned at a certain location exactly coincident or maybe offset a certain distance whatever it may be based on an application and if the sensors needs to be moved for width variations then that's a problem that can cause issues you really need to make sure that if you move the sensor a certain distance this sensor also have to be moved that certain distance so how do we solve that problem the old way of doing it is what is called as a mechanical chasing and in mechanical chasing application you have a master web that is coming here and then there is a sensor here that is chasing the web this is similar to the center guide moving sensor center guide where that second loop was chasing the web for web width variation now just think of that system but take one sensor and put it in on the master web and take the other sensor and put it on the this this follower web and what it's going to do is this sensor has going to have a control loop that is going to move the linear positioner in this case it's going to be in and out of this plane of our monitors here and it's going to move the positioner so that this chasing sensor will match with the master sensor when this is moved and this is connected to the guide sensor this guide sensor is also moving in tandem with the chasing sensor essentially we are changing the guide point of this and this is called as a mechanical casing application so again this is a system where you have a sensor positioner so there's an additional actuator required and it adds complexity depending upon the location where this sensor this Web guide needs to be and where this is it could be quite complicated in terms of accomplishing this and but it's been done it's been done with both electrical electromechanical as well as hydraulic actuators now one of the drawbacks here is that when we want to do the if these sensors needs to be central central sensors that means that we want to justify the lamination based on the average of two sensors then this becomes really complicated really quick what is the modern modern way of doing it is basically to use the the feedback from the master sensor and send that as an electronic guide point adjustment for the guide sensor so in this case the master sensor is recording the web position of the master web and whatever the variation that is seeing here is sent as a feed-forward signal feed-forward signal for the web guide that is following the master web so the web guide aligns the follower web to a guide point that is adjusted by the master censors feedback so electronically it's very simple to do and there's only one control loop here that is the web guide loop and then the only added thing is that it's not a fixed guide point reference now the reference is a feed forward term that come from the feedback from this master sensor and we can also do center guiding with this so you can technically have to master sensors and take the average of those two measurements and take that as the central line position and provide that as a feed forward offset to this edge sensor which can be a single sensor or two sensors so that's what is called as a chasing application now if you want to do more than two webs then it gets complicated mechanically but it has been done in the past and the way it is done is again you have a master web and then there's a chasing sensor and this first part of it is exactly like a chasing application so we have a you have a linear positioner that is closed the loop is closed based on the the chasing sensors feedback that moves the linear positioner in and out of the screen that moves the guide sensor on the top web so that the guide point is adjusted now if you want to follow this position for another layer of web what you have to do is you have to make an synchronize this actuator and this actuator this has been done with hydraulic cylinders as well as electronic actuators but there is a synchronization now you you are looking at there is one control system for this web guide there is one control system for this this chasing moving sensor positioner there's another control system for the slave actuator and then there's another control system for this web day so as you can see it just gets too complicated too quick and the main problem with these kind of things is synchronization this master actuator and the slave actuators may get out of sync with respect to each other in terms of the position now that creates more problems and it can solve a more elegant and a modern way of doing it is again using the master sensor position information and use that as a feed forward to another web guide and in another web guide here we've just shown two web guides technically you can have multiple web guides and you can still do the same thing again it eliminates wear and tear simple expend inexpensive and it's expandable and there's really no limit to how many you can do now what are some of the considerations for electronic coordination first and foremost we want to make sure that the web position variations seeing at the master sensor we can see all of that that means that you need to have a sensor wide enough to be able to see that it really depends upon the application and whether that web guide is whether that web is guided or not now in these examples I showed in these examples I showed like this master web not being guided but there's no reason why we can't ID this web with another web guide and use the the the position of the the web position from this sensor which is which is guiding the web as well and use that for the master sensor can be used what for control and for also for feed-forward signal for all the slave units web backlinks it would be best if the web pad lengths are the same this would provide the best results so that you don't have any delay this is usually not an issue for like steady-state errors but if you have some sinusoidal or non steady-state errors that's when the web path length needs to be ideal and then if you can't do that and if your application is pretty complicated where you need to have you might have sinusoidal variations that you need to match then what you could do is use a dynamics in the feed forward term basically compensating for the path length variations this technique can also be used for some advanced situations where you could use two sensors one sensor further downstream from the web guide and use that average of these two sensors with some additional dynamics to control the position of the web much downstream from the existing website itself you still need one web guide right at the exit of the web one sensor right at the exit of the web guide and then another sensor can be much further downstream and you can use some added dynamics and feed-forward them to do that and then with with these electronic coordination you can also use Deadman and guide point offset so if you don't want the web to align exactly on top of each other we need one web to align at 10mm and the other web to align at negative 10 mm you can do all all those combination of things with electronic coordination so that's kind of some of the quick applications of edge guiding let me just quickly go over some common errors that we see and when we are trying to do edge guiding applications first and foremost the most common one is extreme misalignment so what happens here is that you have a web coming into a web guide with an already which already has an upstream misalignment and this puts the web guide or the actuator at a non-zero steady state condition and that means that this Web guide is already tilted like this here at at a position and this actually limits further correction in this direction the web guide might correct in this direction properly because it has enough stroke but then it may not correct here on this direction where do we see it let's say you have an unwind role if an operator is loading the unwind role they're not loading at the right location where these sensors are justified to either to the center of the machine or to a certain justification with respect to the machine that's the most common thing that we see other places like let's say you have a blonde film line and you have a non centered bubble that's another place that you can see there now what it does is basically correct limits the correction on one side now what is the solution for something like that if you have a sensor that or a controller that can provide a position feedback and you you can take it into a PLC or anything like that then that would help you not really correct for this issue but to use that information to make sure you fix the underlying problem which is either misaligned on windrow or bubble not being in the center and then we can also provide some kind of an alarm signal when the web reaches a certain if it reaches the extreme position or not the other thing is which is very similar here instead of the web is coming at the right location but the sensor is at the wrong location this happens when we do changeover and if if the the operator is not moving the web to the right location that might happen and and as soon as the web guide is put into automatic this is going to move the actuator or web guide to one side because this was the sensor was set for a certain width and the web width has changed and that causes the same kind of follow again is just one of the ways to avoid this is to make sure to use a wider sensor and if you are doing center guiding wider sensor all of these avoids the issue of moving the web and then you can do an electronic guide point adjustment so that you don't have to worry about repositioning the sensor and then same alarms when the web position is reaching the extreme position or an actuator feedback to a PLC or additional monitoring system would also help the other thing that we see is that lets say the correction on the web guide is one inch but then the web that is coming into the web guide has got an oscillation way more than one inch or it could be or it could be something like not just the actuator stroke limit but also the bandwidth but here I just put it as stroke of the actuator but again this is where you need more correction but you don't have it well the only thing that you can do is actually redesign the web guide if you remember from our last last month's presentation the correction from a displacement guide is actually a function of this guide span so if you need larger correction the guide span needs to be larger so sometimes it may not be possible for you to do that because of space limitation and things like that or the the magnitude of disturbance is large enough that you cannot really correct it with one guide so you might have to use multiple web guides there so that would be a possible solution so those are some of the concepts in terms of edge guiding now let me just quickly go over to line guiding and quickly cover some of the few other concepts in line guiding as well so edge guiding is looking at the edge of the web anytime you want to look at a feature on the web you would have to use line guiding or contrast hiding why do we want to do that maybe the the web that you have has got edge variations and you are actually printing on the web this is the most common example is line guiding is used in the printing industry where you have multiple print cylinders and then you want to have multiple the web to be aligned to these printed patterns and it's not typical to see web guide between print units but then once the printing is done you go to the next process like converting like slitting coding laminating anything like that now you don't really want to cut our code at the wrong location so you would justify it based on the printed pattern which is the most important thing right now feature right now so again you follow a line or an edge or a pattern on the web on the surface of the web not the edge of the web this is used anytime when there is feature registration is needed and the pattern doesn't have to be a printed pattern we have done where the web itself has a shape so some kind of an extruded plastic which is cartridges or ribs on the web and the extruded edges are not really straight but the ribs on the extrusion are pretty straight so you want to guide to that you can do that and usually a camera or a visual sensor is used to do that now the advantage is that you can avoid aids variations and this is the only way to do registration based on surface features so if all you care about is making sure that in the subsequent process that process aligns itself to a pattern on the web rather than the edge of the web is the only way to do it it could be expensive depending upon what you want to do and it does require teaching or interactions and most common thing that you see with this as a problem is low contrast features that means that the feature on the web and the background of the web don't have enough contrast variation that you can pick up that feature properly now in terms of line and contrast guiding you can actually do a whole bunch of different things because we're not just looking at the edge of the web you can follow a line and you can say I want to follow the right edge of the line or you can follow a left edge of the line doesn't even have to be a line it can be a negative space that you're following like this white negative space there or you can follow a pattern an edge of the pattern which is kind of straight and then you can also follow a middle of the line so any of those kind of things you can do with line guiding with an appropriate sensor of course so one of the common things that you're going to run across when we do line guiding is intermittent lines so instead of the line being solid you have gaps in the line usually when they print a line it's solid but it's it's an example like this where you have a label and let's say it's a die-cut label and then the little that die-cut has been removed from the matrix so you want to follow that edge like that so again when you have an intermittent light the main problem is that is the sensor can provide you the position information when you are right here but when you're in the gap the sensor doesn't know and one of the things with line guiding is that when you don't see anything there's no way we would know which direction to move because the pattern could be on any side in an edge guiding application if you don't see a web then you know you need to go this direction so that you can see the web and if you see the whole web then you need to go the other direction so that you don't see the whole web in edge guiding we know that but in line guiding there's no way of knowing which direction to go if you don't see a line so this is a problem and the way to address this problem there are a couple of techniques to address this problem one is to get some information about this line itself in terms of how long the line is how fast the web is moving so that you can have some kind of sampling frequency and then you can build you can build building a timer or a timeout timer so that we can say that well if the web is running for this long and I don't see a pattern for this timeout period then do something so you can add something like that this this technique does require knowledge of the pattern and if the pattern changes it needs to be programmed speed and all those kind of things a better way of doing that is to have a loss of contrast signal and lock the web when you don't have that signal so what it means by that is if the sensor sees this line right here it's got a signal when it doesn't see it it has to go into a special condition called as no contrast condition and in that condition the web gate can be locked and then when the line comes back in the it will resume control again now the only drawback with that is if the web moves farther that you are outside the viewing area of the line then that's a problem how do you avoid it well you have a wider sensor if you have a wider sensor let's say you have a four-inch sensor and the web is known to move less than 2 inches then there's no way you will miss this line and in that case the other thing that we see with [Music] with edge guiding is the loss of focus that means that you cannot really install the sensor just like what you would do in an edge guiding sensor the motion of the web guide itself causes plane change and this could cause focus issues and the solution is using a backup folder or a dead bar like what is shown here so if you have a sensor that is looking at the edge of the web a or surface of the web for that matter but when the web guides actuate back and forth this twisting in this pan is going to cause the web to go closer and further away probably sensor and especially when we are trying to look at a feature the amount of light coming back the feature teaching all of those gets affected because of that plane gene so the solution would be to put a dead bar or an idle roller here and then you install the sensor so that it's looking at the web on the dead bar the dead bar is going to stabilize the web itself wrap angle above like five degrees if it's a dead bar and if it's a roller it can be up to fifteen degrees but no more than that and then again we follow all the same procedures in terms of how far the sensor can be from the web guide and things like that so that's a way in which we can stabilize the web and the thing is that this is not only applicable for line guiding it's also applicable for edge guiding let's say you have a pretty big web guide and it's got a lot of correction and that correction causes the plane change a significant plane change you can put a dead bar right there and then put the sensor before or after if you haven't like a small five degree wrap then it doesn't matter if you put it before or after the dead bar and then that will stabilize the web and that will make sure that the web doesn't touch the sensor when this rotates back and forth a couple of quick concepts on other line guiding applications now if you have an unwind roll how do you install the line guide sensor or a contrast sensor in in the other case this would have been freeze fan just because we need to support this the web to avoid the focus issues there has to be a shifting idea that's installed at the exit of the unwind and this idler or a dead bar has to move with the unwind and then the sensor has to be installed so that it can look at the web on the roller and then this sensor has to be fixed to the Machine frame it cannot move with the courage and we do the same thing with rewind the only difference here is that again the sensor has to move with the rewind in this case and then you can have a fixed idler or a dead bar in this in this pan right before it goes into the rewind so those are the quick application summaries of an advanced guiding concepts and just to summarize what we talked about today our recommendation would be if at all possible use center guiding Center guiding provides or averages the two edge position so it inherently filters or providing an averaging effect for edge variations and then especially if you have web width variation you can avoid some of the common mistakes with improper sensor positioning and things like that you can also use the two sensors to measure web width that's an additional signal that you can use for your quality control purposes if you have some complicated materials where you don't have a straight edge and then it's causing problems we should look into deadband in the in the controller and then edge filtering these are a couple of things that can significantly improve the performance of the guiding system obviously the sensors are unaffected by the material changes you're going to avoid a lot of other issues that you would see with mention on sensors coordinated controlled when you want to do multiple web lamination it's better accomplished with electronic guide file guide point changes this prevent any kind of mechanical wear and tear reduces the complexity of the system and can provide a good performance when compared to other mechanical system and as an additional feedback on your web web line itself we would recommend if you can get actuator position feedback that can help and if you are monitoring that information that can help identify and prevent any performance issues that may be causing from an upstream process so best example would be like improperly position unwind or some kind of a steady state shift that is coming from an upstream process or misaligned order or anything like that in terms of line guiding the loss of line signal if you are able to get that then that would be good because some of the sensors that are available might not have a wider sensing range so if you go outside the sensing range and you don't know that you've gone outside the sensing range then at that point the web is not guided it's just free-floating kind of thing so if you have a loss of line signal then you can use that into your PLC and avoid any issues that you might have it's a quick summary of what we talked about again some additional resources that are available on our web site feel free to go to our website and take a look at that and then our contact information so once again we really appreciate your time today to to listen to our presentation and we'll open up to any questions okay there's a question here that says that shouldn't the reboil sensor position be in the moving station that is correct I think that's all we had it here so the sensor is actually moving with the rewind here and it's chasing the web it's not actually guiding the web if you look at the unwind it's the opposite the sensor is actually fixed it's not really clear here but it's not attached to the carriage the sensor is fixed and then that's how it is okay okay is there a reliable web sensor for high temperature 200 degree C for clear films I am not aware of anything our sensors are rated for 85 C and they can work with clear films most often clear films ultrasonic sensors are used but at 200 C the frequency of the crystal would be affected by it so we might have to get back to you on that if we know of any sensor that can be used at 200 C there are some other questions that are specific to our product which we will answer separately you know mind your application where the entire winder is on a shifting base where is the idle idle sensor placement in the machine at the winder Inlet idly or further downstream or close to the actual winding location okay so that's a great question let's see so ideally in this binder or rewind it's it's kind of the same thing here ideally we want to put this as close to the winder as possible that would be the ideal location as if you have a roller that is going to take care of the diameter variations then putting this roller putting this sensor as close as possible here would be the ideal location farther away again we're adding delay to the system there's another thing that is not considered or not talked about enough is that the stiffness of this mechanical arm that is holding this sensor is an important factor if this if the arm is not stiff enough that's going to cause minor instability so as you put it further away at the stiffness or you got to make it really beefier to be able to have a stiff sensor there so ideally as close to the binder as possible is the ideal location okay are there other filtering methods besides exponential moving average that might be more optimal exponential moving average the choice of that is mainly because of the fact that it is it is easy to implement it's a pretty simple filter factor that's the reason why it's more popular let me see if Carlo has any other comments about that but to me exponential moving average is the simplest one and easiest one for us to implement it this is just purely for filtering the edge position obviously you can have some advanced control system where it has a filter built into the controller itself like an adaptive control or things like that so there is a question about upgradeable upgrading to wider sensor yes it's possible we can upgrade it to any of the wider sensors okay any other questions or comments okay hopefully you had a chance to take this bowl and just to give you an idea okay so a wide group of people mostly in converting and then also in terms of job titles operations maintenance plant engineer and then design engineering and Rd are kind of a key areas here okay so if there are no other questions we will conclude this webinar we will also follow up with people who ask questions in case they have any additional clarification and we will continue the series with another webinar next month and we have collected some feedback from attendees about what would be the ideal topic and based on that we're going to have the next month's webinar we really appreciate your time and to join us for this webinar this webinar will be recorded and we should be able to post that on our website within the next few days and we look forward to seeing you next month thank you so much have a great day

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# Web Guiding Fundamentals

URL: https://r2r.tech/videos/web-guiding-fundamentals.md

## Web Guiding Fundamentals: Topics in this webinar



- Web guiding Terminology
- Why we need web guides?
- Types of web guides: Terminal and Intermediate web guides
- Normal entry rule
- Main components of a web guiding system
- Unwind web guide structure
- Rewind web guide structure
- Terminal web guides design and installation considerations
- Offset-pivot guide or displacement guide design and installation considerations
- Steering or remotely pivoted web guide design and installation considerations
- End and center pivoted web guide design and installation considerations
- Actuator terminology
- Hydraulic actuator
- Electro-mechanical actuators
- Electro-mechanical actuator terminology
- Actuator sizing factors
- Sensor terminology
- Types of sensors
- Web guide controller and terminology
- Common web guide controller structure
- Open loop lateral web dynamics
- Closed-loop lateral web dynamics
- Web guiding performance
- Factors affecting web guiding performance
- How accurately can we guide a web?
- Web guiding fundamentals summary

## Transcript

is going to be recorded and then we will also share the link once the webinar is done so that we can you can take a look at it after afterwards I will be your presenter I am Arvind Seshadri I'm a troll to role technologies just to give you a background I have been with troll troll for almost 6 years now and before that I was at Oklahoma State University I got my PhD in mechanical and aerospace engineering specializing in dynamics and control of roll-to-roll machines so topics such as web guiding tension control registration or some of the things that are unfamiliar with as we go along in this presentation we'll also have some polls or some questions so that we get to know a little bit more about you and what are some of the problems and hopefully we can take advantage of that and guide the presentation along the way once again we're about ready to start the webinar and as part of that let me just give you a quick poll if you can answer that really quick in the next minute or so that will help me in terms of some of the topics that will be covered today and we can look at how we can tailor that to the audience so basically we just wanted to know a little bit more about your knowledge about web guiding there are some people who might have no knowledge about web guiding there are some who might just know what a web guide is how it works or some of them are well versed in being a designer they can design web guides or design web guides into their machines or some of them could be even experts that are called upon when where you have any issues with web guiding in your operation so I'll give a just a quick minute or 30 seconds to make sure that everybody had a to answer this question okay seems like we have a pretty good mix of audience here people ranging from as people with no knowledge about web guiding and also some experts and web guiding okay thank you for taking that poll that gives me a pretty good idea on how we can proceed with the presentation okay so before we start web guiding let's just look at some of the common terminologies or names that are used for web guiding web guiding is also referred to as steering some people call us tracking depending upon whether we are guiding the edge of the web or a feature on the web it might be called as edge guiding line guiding contrast guiding more technical term would be like lateral control or lateral registration these are some common terms that are used in the academia when we are talking about guiding sometimes it's also called as CD registration CD where see these stands for cross machine Direction registration and then lateral alignment and if you're from eastern part of the world in Asia it's commonly referred to as EPC or edge position control or line position control essentially all of this means the same thing that is guiding or a web guide is used to position the web at the desired cross machine direction and it is done so that we can enable efficient transport if the web is not guided then we have issues with the web crashing into the machine quality issues wastes and things like that so why do we need web guiding all their army fully mainly for reasons why we need web guiding first and foremost is that materials are not perfect you might have a poorly bound roll that is not one properly or deliberately wound row with an oscillation on it and when we are trying to feed it into your role to the old machine you need to guide it so that it aligns with your process some materials may have thickness variation this could be like gauge band variation either during coding or forming processes especially with paper mills different gauge papers may track differently or slide differently splices whenever you have change from one role to another when you are joining two roles of web it might be a step change or it might also be like an angular misalignment of the splice and then some materials have a natural curvature to them which is called as camber so the material properties when the materials are not perfect that's going to have the web miss track in your machine it could also be due to machine itself so either you have machines with out of round rollers like a crown or a concave or a convex roller whenever you have a variation in the diameter of the roller that's a problem or the rollers are not aligned properly with respect to each other that could also cause the webs to miss track you might also have tension control issues and if you don't have enough tension you don't have traction then that's going to be an issue and whenever you have acceleration or deceleration that might also cause the web to miss track it could also be due to processes for example if you have a coding process and you have uneven coding across the width of the web that's going to cause issues with tracking and also some processes where you could have air entrained between the web and the roller that would cause the web to loose fraction and miss track so that could also be an issue and that's why we need web carry finally operators mainly when they are splicing the web or when they are putting a new parent role into their roll-to-roll machine they may not Center it or they may not put it at the right location that might also cause an issue and that might need web guiding so web guides are necessary at different locations of the machine because you might need alignment at different parts of the machine so that's that's the main thing with web guiding is you have to put a web guide in front of any process that requires web alignment just to give you an example let's say you are laminating something and we have two layers of web coming in to this lamination process at this point you would need a web guide so that you can online this layer and this layer with respect to each other the guides that are used within the machine or called as intermediate guides or they are intermediate to the machine and the guides that are used at the entry and exit of the machines or call as terminal guides so we're going to look at all of these in detail but that gives you an idea of why we need web guides and where we need web guides in terms of the location as I mentioned when you have a web guide that that is located at the entry and exit of the machine they are called as terminal web guides there are lots of names for these and some of the common names are shifting stand a shifting base a shifting side lay on role positioning stands if you're in the metals industry it might be uncoil or recoil and in other industries it might be called pay off and tension real and specifically in these presentations and in our terminologies we call them as unwind and rewind guide an unwind guide is something that is at the entry of your old troll machine while a rewind guide is at the winder or the exit of a roll-to-roll machine so these are some of the terms that are used for terminal guides and in terms of intermediate guides these are the web guides that are used within the process within the machine there are certainly multiple types of these web guides and the most common one is what is called as an offset pivot guide other names for opposite favorite guides or displacement guides positive displacement guide pivot frame or a table guide the second most commonly used intermediate web guide is a remotely pivoted guide that's a technical norm at term but most commonly it's called as a steering guide or steering roller or a swivel roller and then there are other less common web guides like an pivoted guide or center pivoted guide and then even turn bars are all available well we'll take a little bit deeper look at all of these different kinds as we go along in this presentation but most of these web guides work on a basic fundamental principle and that is what we call it as normal entry so what is normal entry say normal entry is basically is a web approaching a roller will always align itself perpendicular to the axis of rotation of the roller as you see in this video right here let me restart that as soon as the the roller on the left has a misalignment the web started to track and it started to move in such a way that it will approach the roller on the Left perpendicular to the axis of the rotation this is the fundamental principle that is used in most of the intermediate web bags that we are going to see and what's happening here is that the web is essentially behaving like a beam and the angular displacement on this left-hand side is bending the team and it's causing the beam to bend and that's what it's causing the web to track to this side there are lots of dynamics involved in this process how fast the web moves how much does it move all of those depends upon the transport conditions the what type of web it is what kind of traction you have and things like that and obviously the static behavior is that at steady state once this angle is said how much is it going to move are we going to see any movement on this side as you can notice that when this web moved the upstream roller the web was still there it was maintaining there because it was able to have enough traction so that the lateral forces at the moment that is acting there was not able to make the web move and whenever we have a motion like this bending occurs bending in term means that there are stresses developed in the web so you're going to have a tight side and a slack side and there going to be a tension profile here so these are important to understand for us in order to have a successful web guiding application or execution of a web cam so in terms of a basic web guiding system we are mainly dealing with four main items apart from the web we're mainly dealing with four main items one is the guide structure or the mechanism this is the device that is actually making contact with the web and that's the one that is need to be moved or it moves the web and there are different types of guide structures that we will go through the other component of web guiding system is an actuator so actuator is something that takes an electrical signal and then it converts that into physical motion so that it moves the guide structure so that the web can be loved rated at the desired location the third and one of the most important components of a web guiding system is a sensor the sensor is the device that provides the feedback the sensor is the one that tells us where the web is where means it's inferring the position and then finally that signal is sent to a controller and the controller is made mainly the intelligence or the brains that that takes that sensor signal and computes the corrective action that is acquired so that the actuator can move the guide mechanism to the location where we can get the desired web position again another schematic of how the components of the web guides are so web is a part of the web guiding system and then you have the mechanism there's an actuator inside the mechanism the sensor gets the position feedback of where the web is sends that information to the controller controller then computes an error and it sends the command to the actuator so that the mechanism can be moved to position the web at the right location so this is a closed-loop feedback control system that is a main part of a web guiding system so let's dive into detail about different components of the web guide first we'll start off with guide structures and look at how guide structures are with different types of web guides that we saw so first and foremost we have the unwind web guide structure in this case you have a parent role and that is feeding the web into your machine and this role is on a shifting stand or a base that is supported by typically linear bearings and then there's an actuator there that connects the moving state and with the fixed base and then there's a sensor here that is looking at the position of the web so the main objective of an unwind web guide is to ensure that the web that is fed into the process is at the desired location and because of that you have a fixed sensor that is fixed to a machine frame and then this stand actually moves in and out of the monitor that we have here it's going to go in and out and the the feedback from the sensors used to make this unwind guide move in and out so that it can position at the right location one thing I wanted to point out is that the there is a shifting idler when I say shifting idler it means that this idler is attached to this moving base the main reason why we do that is that if we put a sensor right here it is not an ideal location just because of the fact that when the diameter of this roller changes you're going to have the web plane go in and out and if that happens that's going to affect your guiding so typically you would see a shifting idler I doesn't have to be one it can be multiple it could also be a whole frame with a lot of rollers here all that we need to do is that we need to put the sensor just downstream of the last shifting idler and then the sensor is fixed to the Machine frame so that we can guide the web so those are the main things with an unwind guide now when we look at rewind guide rewind even though we call it as a guiding it's not actually guiding the web it's actually chasing the web so the the the main thing that is unique about this is that in a rewind system you have a sensor that is attached to the rewind frame all of the things in terms of the carriage it's exactly the same you have a sensor that is attached to the rewind stand so that when the rewind moves the sensor also moves and then you have a fixed idler right after this this moving sensor like I mentioned rewind is not really guiding the web it's actually chasing the web and the main reason why we do that is that we need to maintain the relative position of the web and the rewind role and if we put the sensor on a fixed frame and look at this rewind role then we will not know the relative position between those two that's the main reason why we attach the sensor on to the moving rewind stand so that the sensor gives us indirectly the position of the rewind stand and the objective is to make sure that we move the rewind stand so that the middle of the sensor or the guide point of the sensor matches to the location of the web again like I mentioned it's not really guiding the web we are chasing the web so that the the rewind role would be at the right location to get the web bound properly so just to summarize about these two terminal guides we can look at what are the things that we need to have a good rewind or unwind guiding system first of all in terms of design we need to make sure that the mechanical structure and rigidity and stiffness or design properly we are moving a big mass and depending upon the type of web maybe metals it may be thousands of pounds multiple thousands of pounds that we are trying to move and we need to make sure that the structure is rigid enough so that we can avoid any mechanical resonance so the natural frequency of the structure should be at least three to four times the operating frequency of the control system the other thing we need to consider especially with these kind of guides is that we need to size the actuator properly when we talk about sizing the actuator what we are talking about is it should have enough thrust so that it can push the mass it has enough thrust to overcome the static friction and it also has enough thrust to provide the desired acceleration to reject the disturbances or errors that may be there just like the mechanical structural rigidity we need to also make sure that the actuator coupling and the actuator stiffness are all counted for any play in the actuator coupling is going to reduce the stiffness of the overall system that's going to destabilize your system in terms of installation consideration the main thing that we want to look for in these type of guides is the location of the sensor with respect to the moving Stan either it's fixed to the machine frame or it's it moving with the machine with the carriage that's the main thing these web guides are simple that's one of the advantages of these web guides and these web guides really do not have to take advantage of the normal integral because all the rollers there are parallel to each other so there's not going to be any misalignment in them so there's going to be less amount of stresses on the web the disadvantages with these kind of web guides well first of all you need a high thrust actuator especially when you have a larger mass to move and it's not cost-effective if you really want good performance from a web guide if you wanted to reject the high frequency disturbance then this might not be a good choice for us now moving over to intermediate web guides we have a displacement web guide this is another type of one of the most commonly used web guide that you are going to see and we would recommend this as the first choice for any web guiding application one of the main reasons for that is it actually displaces the web and in this Web guide it's it's not bending the web the reason why it's not bending the web is you have this entry span and you have a 90 degree wrap and then you have the plane of the carriage right here when this carriage pivots the pivot point is shown here but that's a mistake it should have been right at the edge of right here so when when this carriage rotates pivots about the pivot point which is at this point right there these two rollers are actually moving in tandem so there's no bending in this region and then in these pans since they are perpendicular that motion is a pure twist so really there is no bending in this kind of a web guide and if the web guide is designed properly then these web guides can have one to one ratio in the sense that if you move the web guide one unit then the web will actually move one unit so that's why we we call them as a perfect web guide and I do see a question here that says that would you agree that an offset period guide acts on a different principle other than normal entry that is correct and just like I explained because these two rollers are parallel to each other there is no bending in the span and since these two entry and exit rollers are perpendicular or the wrap angle are perpendicular this span is perpendicular to the plane of motion of the web guide they are going to be in twist so there's no bending and when there is no bending there's no normal entry coming into picture there so like I mentioned the twist is an important design part and and this would be our first choice for us in terms of applying it in any web web guiding situation so in stones of installation again we want to make sure that we have a 90 degree rap at the entry and exit of the roller and then there are some considerations on how what is the span length at the entry and exit so usually you can get away with half a web width usually we recommend about one to do web bits if possible and if you have a stiffer web like metals like you might need much longer entry and exit span we want to locate the sensor as close as possible this is true for any web guide it doesn't matter if it's displacement guide unwind guide rewind guide any web guide we want to have the sensor as close as possible in the span where the guiding action takes place and then in this case the recommendation is to be within the first half of the exit span and then how long this span really depends upon how much correction you're looking for typically these carriages are allowed to pivot only about five to ten degrees so if you want larger correction then you can make these pants longer the main thing is that you need to make sure that the plane of motion of the carriage is perpendicular to the entry and exit span so that you can create a pure twist on these spans and then as long as these rollers are moving in tandem or parallel to each other then we will have the desired effect they don't have to be on the same carriage they can be on different carriages as long as we are able to move have them parallel to each other you can even have a process here you don't really have to have just two rollers you can have multiple rollers so it provides a lot of flexibility here and and and and the guiding action is actually happening in the exit span so what not to do so we don't want to install the sensor too far away or we don't want to install the sensor in the next pan this is mainly for control system purposes and stability so when the web guide makes a corrective action that action is not seen at the sensor immediately so if you're running really fast you might get away with moving these sensor it's a little farther down but if you're running slow whenever this Web guide moves here you would see that motion if the sensor is as close to the down to the exit roller as possible if you install it here or here especially when the web stops and there is a small error the web guide would keep moving and that might cause the web to break or have unintended consequences so we don't really want to have the sensor further away or a next ban and we don't even we don't also want to have a scenario where you have an angle that is not ninety degrees so as I mentioned if you have a ninety degree wrap you have twists as soon as you introduce something which is deviating more from the 90 degree you start creating bending in the web so these kind of bending is going to act as understeering the web it's going to cause bending that's going to understeer the web and it also causes distortions and guide instability so we don't really want to have any of these conditions on the contrary if you have a span exit span that is spread out like this this is going to oversteer the web again it's the bending effect that is causing that and we really don't want to do that so ideal scenario would be to have a 90 degree wrap in and out but there are other options for wrapping the web there you don't have to have it just like this what like how we showed it's an inverted u configuration you can have the web going like this or like this like a Z configuration depending upon the space and all those things and obviously you can rotate all of these 90 degrees upside down just rotate all of them so you would have about 16 different configurations that you can do with these webpage all in all need to make sure that the entry and exit span or perpendicular to the plane of motion of the web guide and all of these conditions satisfy that have the sensor as close to the web guide as possible we can satisfy that and then you can have multiple configurations for these so in summary the displacement guide the main design consideration when when somebody is asked to design a web guide displacement guide is what is the desired correction then that kind of determines our span length for the guide span other than that in in terms of installation it really depends upon how much space you have so you can design the entry in the exit span and then if you have a stiffer web you might have to exaggerate that entry and exit span make sure that we have 90-degree wrap and then wrap the web guide based on the path so one of the other parts would be in the same direction the web came in and things like that advantages these are simple to install the proper installation imports the least amount of stress on the web and then it's pretty versatile I put a disadvantage there but it's really not a disadvantage but I do want to have I do want to have that here it's like the the maximum correction that you can get is designed in so in another type of web guide where we can take advantage of steering or our bending we can get more than what the guide moves so the second choice for us would be a steering guide and in in in terms of how it works it's a little bit different you got a single roller and this is the top view and this is kind of the side view and this roller is installed on two raceways they are at an angle so the web can actually forms an arc like that so it moves and forms an arc back and forth that's that's the that's how we are changing the axis of rotation and in this Web guide we are creating a bending so there's a bending action here it's displacing as well as bending then in terms of the entry and the exit span there are some guidelines for that as well and we'll go through that this is not an ideal choice for us or this is not our first choice because as I said it's bending it so it's introducing stress if it's not installed properly it can cause wrinkles creasing web tear and edge quality edge stresses and things like that so I just wanted to stop quickly and answer a couple of questions how do we determine the minimum entry and exit span that really depends upon your stiffness of the web and things like that the average stress there is a guidelines for that that I can share later on but it really depends upon the tension the Youngs modulus of the web and then the width of the web and then the span length so there is a formula where we can get the minimum entry and exit span links and the entry and exit span need not be the same like they can have different lengths also how do you determine the correct length of the displaced displacement guide table or the guide table length is basically based on how much correction that you need like I mentioned usually the tables are made to rotate about 5 to 15 degrees so so the displacement that you need need would be let's say L is the length of the span on the guide table and theta would be the angle of displacement the correction would be L sine theta theta so that is the maximum correction you can get so based on what maximum correction you need you can get the length of the the guides ya the guide span on a displacement guide and theta is the upper limit we can say 15 degrees so okay switching back to the steering guide in terms of installation what do we need to look for well we need to make sure that the exit span is perpendicular to the plane of motion of the web guide so again the main thing that we are trying to do with this is to make sure that the exit span is in pure twist this is where the this allows us to have the least amount of stress in the web so we want to do that now the entry and the exit span length of that is also depending upon the stiffness of the web you typically need a longer entry span for a rewind guide because the that the motion of the web guide or the displacement of the web happens because of bending and so you have to follow those guidelines in terms of if you have a stiffer web you need to have a longer span so that you can allow the bending to happen but normally it's about one to five times the width of the web and then the exit span can be half a web width and there's also minimum formula for finding out the minimum spanning there in terms of other things here let me go back here and talk a little bit about the instant sender like I mentioned there is a race way to race race here and they are angled so that you can have the web guide go around an arc and the center of the arc is called the instant Center this is important we need to make sure that the instant center is within the span and it's at a certain distance about half the length of the span or up to two-thirds the length of the span again these are all numbers coming from the dynamic model of the web guide and the dynamics of the web itself and if you don't follow those conditions then you can have a web guide oversteering understeering creating an awful lot of stresses may be wrinkled slack edges tight edges and all those kind of things so but the main things that we want to look for is this angle make sure that it's 90 degrees and then you have an entry span that is pretty long you can have different wrap here we don't want to go more than 45 degrees on either side that is fine when you do that what you're doing is you're adding a twisting per se so whenever it goes away from this 90 degrees it's not pure bending that is bending and twisting that isn't Maul there and then we want to have an angle here because again when you put bending stresses here you have the possibility of that what we call its moment transfer occur here so the motion of this roller can actually move the web upstream of the guide roller so in order to avoid that we want to have certain conditions here and then we also want this span shorter so that it becomes harder for that moment transfer to occur so those are some of the guidelines for installation of a steering guide and again sensor as close as possible now what not to do same thing we don't want to put the sensor too far away one of the things that is not really evident is that we don't want to put the plane of motion of the web guide at anything other than 90 degrees it's not this angle between the entry and the exit span that needs to be 90 degrees it's actually the angle of the plane of motion of web guide and the exit roller that's what determines whether you're going to have a twisting action that's going to happen here or not so when you when you have something like that you're going to introduce bending in this span and when you start bending a short span it's not a good sign so we don't really want to do that so that's the main reason why we need to have the plane of motion perpendicular not really the entry and the exit span but the plane of motion and then like I mentioned if you have the entry span and the pre entry span longer then the entry span then you could have moment transfer happening that's something that you don't want to do either in terms of wrap angles are pretty simple you can have something going up like that or going down like that as long as we follow this condition that exit span is perpendicular to the plane of motion then we are in good shape just to summarize the design consideration desired correction is one of the main things there and the raceways that we have on the steering guides we don't want to angle them more than 25 degrees so anywhere between the like 5 to 20 degrees would be the ideal one in terms of installation steering guide is lot more complicated to install you have to consider the stiffness of the web that determines the entry span length and then you also need to make sure that you're not putting too much bending stress on the web based on how stiff your web is and then the location of the instance center which depends upon the raceway angles again that depends upon the length of the entry span so there are lots of things going on here that we need to consider for proper installation of a steering guide and that's one of the reasons why these web guides are prone to have a lot of issues because they're not properly installed in terms of advantages there they are simple so they're cost-effective it's just a single roller so it's it's it's inexpensive but it comes with other things that increase the overall cost of ownership it's hard to install a lot of attention to detail is required and a lot of these have especially because of the bending and things like that loss of traction or anything like a moment transfer occurring can actually amplify the error so a poorly installed or poorly designed steering guide can actually produce error more amplify the error then then what it's intended to do there are a few other types of web guides there are not used commonly but they are Center pivoted guide again they are going to use the normal entry rule to try to steer or guide the web so there's bending that's going to happen so we're going to have similar considerations in terms of entry span pre-entry span and exiting span because they don't have any displacement like in a steering guide you displace and change the angle of rotation in these guides it's only the angle of rotation they are usually really slow in terms of response they're not an ideal choice in in modern guiding principles but the same design considerations have to be followed whereas in a steering guide so that kind of gives us a quick summary about different web guides and how to install them and things like that so the next part of web guiding is the actuators so in terms of actuators there are lots of terminology there is involved and some of them are thrust or power how fast the accelerator is what is the correction speed what is the acceleration stroke lling mounting what type of coupling that we have and things like that actuators are pretty common or pretty standard right now it's not as as installation of a web guide or the sensor but it is an important part of a web guiding system the older actuators were either pneumatic or hydraulic you had a hydraulic pump pumping a double-acting cylinder and moving the the web guide structure these were more common in the 50s and up to about maybe 90s before the electronic electromechanical actuators started coming into the market so you could have pneumatic actuators or hydraulic actuators the hydraulic actuators have the advantage that it can provide pretty high trust and can shift large loads pretty quickly even now in metals industry hydraulic actuators are pretty common you can see them but the problems are that it's a problem with maintenance you need to balance the valves and stuff like that change the filters they could cost leak and this could contaminate your product and then the precision and accuracy that you can get with an electronic actuator or electric actuator is not something that you can expect in an hydraulic actuator so most web guides nowadays are going to use electromechanical actuators like what I have shown here these actuators usually have a motor that drives a belt pulley kind of a system and there's usually a lead screw a ball screw or a roller screw that converts the rotary motion into linear motion at the end of the actuator so some some common terminologies that you would see with actuators are what is the maximum current voltage power whenever we have something with the lead screw or a pitch then that's a common term that you're going to see what is the lead of the actuator pitch of the actuator gearing ratio backlash is another thing that you would commonly see with electric actuators especially with low end lead screw actuators and resolution again what is the smallest movement that an actuator can produce that's another term bad drive is some a common terminology that you would see especially if you are installing a web guide that has to work against gravity and then types of actuators you have inline and reverse parallel some actuators have limit switches or n stops and then type of motor used in the actuator you would commonly see servos stepper brushed or brushless DC motor so actuators are providing the driving force to the guide structure so that it can position the web in terms of trust the trust is the amount of force that is exerted by the actuator to move the guide structure and this trust really depends upon as we saw before mass of the structure that we are trying to move what is the friction there how fast you want to move and sometimes gravity as well if you are acting against gravity in terms of sizing actuators these are some of the things that we would need to know to size an actuator properly web blind speed mainly because if you have a slow-moving web the the the the maximum disturbance frequency that you can get really depends upon the speed of transport of the web so if you're just moving at 100 feet per minute you might not need a high dynamic response while if you are moving at really high speed you might need a much higher dynamic response that's the main reason why we need that and then the the dynamic response is related to the acceleration acceleration is related to the thrust so that's why line speed becomes important guide structure weight and roll weight again if you are trying to move a big mass we need to know that what type of bearing you are using so that what is the breakaway force that we need to overcome based on the coefficient of friction of the bearing and then what kind of disturbances we are trying to correct for again like I said they there is a correlation between the amount of disturbance that can propagate through a roll-to-roll machine and that really depends upon the speed of the web the faster you go higher frequency disturbances can go through so the web access like a low-pass filter and then the acceleration and then if you have to look at any gravitational effects so these are some of the key factors that are involved in properly sizing an actuator but like I said actuators are pretty straightforward nowadays just need to have some basic questions answered and then we'll be good to go one of the most important parts of web guiding system is the sensor it is important because what you can't measure you can't control so if you have a poor sensor and you're not able to measure the position properly then there's no way that we can get the accuracy that we need in terms of sensor terminologies range resolution accuracy linearity those are some things that you would see type of sensors infrared optical ultrasonic air type of things that you are trying to look for in terms of web position or you're trying to look at edge of a web or you're trying to look for a line on the web or a contrasting feature on the web how much how fast can the sensor measure and then passed line and plane change these are not important nowadays but older ultrasonic sensors have issues with passed line changes so you can't have the web too close to the ultrasonic emitter because it might reflect the sound waves in a way that doesn't provide an accurate measurement and then temperature drift again ultrasonic sensors can have issues with temperature drift when we have the piezoelectric crystal frequency changes then what kind of a signal output that you get from the sensor that's some of the terminologies so essentially a range of a sensor is what is the maximum lateral displacement that the sensor can measure a most often for web guiding applications range is not that important just because of the fact that you're controlling you're going to bring it in but it does become a critical when you have web with changes and things like that so most often range is like how much change in the lateral position that you can measure with the sensor resolution is the minimum lateral position change that the sensor can see so if you want to guide a web to five thousandth of a inch then you better have it a sensor that can have 4 X or 2x higher resolution than the guiding accuracy accuracy is basically an indication of how close the sensor measurement is to the real measurement this becomes important for certain types of sensors that are affected by materials material properties like opacity porosity and things like that so this is an important characteristic of a sensor and then linearity is like what how consistent is your measurement with respect to the actual position across the entire range of the sensor that's what linearity means so in terms of sensing why is it important like I mentioned some sensors have issues with material properties like opacity porosity or reflectivity or they may be affected by environmental issues such as air flow temperature changes or vacuum and things like that so if we can't measure we can't control so that's why sensing is an important part of having a good guiding performance most often you would see these type of sensors we refer to as opposing beam or fork-style or horseshoe style there are lots of different names for it basically how this works is you have a one omitting a certain type of signal and the other arm receiving that signal and then the web that goes in between it blocks it it's a pretty simple technology work sensing principle and it works well for a lot of different cases the problem happens whenever depending upon this type of sensor signal that you have if the web allows that signal to leak through when it went when it's blocked by the web that's where the problem act occurs so we talked about linearity the solution range all of those things are affected by this kind of sensor whenever that change occurs this sensing signal can be air it could be optical like visible light or infrared light or even UV light and then it could also be sound like ultrasonic it really doesn't matter and then whether this material is opaque or porous to that signal is what it matters in terms of how well you can guide and often manufacturers recommend different sensors for different materials and different conditions so you will have a plethora of sensing technologies out there like I said the main disadvantages is material dependent gain change occurs and then requires calibration if you want to get a really good guiding performance there are other sensor technologies out there like ours which are not affected by material properties and some of the environmental conditions I'm not going to go into detail about our sensor technology here but just going to give you a quick overview it's basically a high accuracy direct measurement or absolute measurement and then our resolution does not depend upon the range and it can work with any material I'll give you some resources the end of the presentation so that you can take a look at our stuff so that's the sensor so finally the final component of the web guiding system is the controller so the controller is basically the central processor sir that takes the sensor input and then computes what the corrective action needs to be and then it sends that information to the actuator nowadays the controllers also include a human machine interface like an operator interface but previously the controller could be standalone it doesn't really didn't really have an interface and even the controller could be analog in a sense of electrical analog or pneumatic analog controllers so basically a controller is taking the sensor signal and then making the necessary computation so that the actuator can be positioned at the desired location in terms of terminology gain is one of the most common things that you're going to hear in controllers that's basically saying how quickly or what kind of a dynamic response that you need that's basically the gain is going to do that other things that you're going to see is operating voltage power consumption whether you have a operator interface or not and then whether this is a controller for a servo motor or stepper motor or whatever that is they have drives or drivers for it how many sensor inputs you have does it have Ethernet connectivity does it have remote control and stuff like that in terms of the control structure most control systems have web guide control systems have this kind of a structure where you have a fixed gain proportional control and you really don't need anything more than a proportional control for a web guide because there's integrator built into it but usually you have something like you have a motor it might have a current loop it might also have a velocity loop with a tachometer or something like that and then you have a guide structure which has its own transmission ratio and there's the web dynamic which is unknown web dynamics means that if you move the guide 1mm how much is the web going to move that really depends upon transport conditions the stiffness of the web tension and all those kind of things and then finally you have a sensor that measures the edge position and then it sends that to a position controller that's going to drive all of these loops so this is a pretty simple architecture for most web guide controllers they are fixed gain and most often they are detuned because of the stability and all the other reasons most web guides their controller is kind of detuned for the conditions if you want to get the best out of it you would need to retune them and the tuning has to be based on the optimal performance because the web dynamics is unknown most often DC motors or DC servo motors or stepper motors are used in this kind of a control structure it's pretty common there are some other advanced control technologies which are like adaptive control where the controller can adapt or learn on the fly and tuning may not be required when we say learning on the fly it means that maybe it adapts to sensor gain changes or the sensor the dynamics of the web and all those kind of things it's possible that we can have a controller that can adapt in our case we have a pretty similar structure as the one I showed in the first one it's still a fixed game controller but with with some motion control aspects built into it in terms of s curving the position and having trajectories for velocity we can increase the stability of the controller and provide a pretty aggressive output performance again pretty similar you can have a current loop a position loop if you have an encoder and then position of the actuator here and then the finally the the web position which includes the web dynamics just to give you an idea we have a lot of different things that we can do with the controller but the dynamics is basically if you move the this is showing a step response open-loop step response for a web this was like a nonwoven web that we had at different speeds and see how it behaves and you can see that when you have a step it I mean even though it's open-loop it's trying to get there and and the dynamics open loop dynamics is different based on how fast you're running so faster you are running it gets to that desired location as fast as possible but the slower you are running it takes longer to get to that desired location again this is an open loop response this is the the the final part of the whole web guiding thing which is the dynamics of the web now if we have add a controller to it and this was our controller then we can have a much better response and we can actually push the web guide in this case at the two different speeds that we were running at this was the reference change and this was the actual response of the web guide at the sensor and then when we have another sensor installed one span downstream you can see how long it takes for that to go to again when we have a step response you can we were able to get up to about 170 millimeters per second or like seven inches per second this is about close to 70 percent improvement over an open-loop response and again this is closed-loop that means you are actually actively guiding the web so with the proper control structure design you can get like a high bandwidth system close to six Hertz or something like that and then even get a well damped system so you can actually have an aggressive correction if you need to in terms of the characteristics of a good web guiding system is that it should have the ability to attenuate disturbances easy to tune obviously it needs to be stable has good processing power so that it can process multiple sensors have industrial Ethernet connectivity these are for advanced functionalities and then sparks and intelligence for industry 4.0 so the final question here is that well you have a web guide and we talked about all these different things what is the accuracy or how how accurately can you guide a web it actually depends like I mentioned there are lots of different parameters there that are going to affect the accuracy of the web guide at them if you are just dealing with the steady-state error we can expect plus or minus 0.25 millimeters if you have a good machine and a perfect material this is what you can expect and higher accuracies are possible like in printed electronics and stuff like that you can get much higher accuracy but again we're dealing with steady-state errors you have a good edge and all those kind of things this is possible but the problem is that most web guides are going to come in to transient errors these are either disturbances or materials or material properties that are going to affect the the disturbance at the web guide now if you are trying to correct a transient error it really depends upon what is the magnitude of the error what is the frequency of the error and so on and so forth and another important thing that we need to consider is that these transient errors can actually propagate downstream of the sensor and these are called what are called as V generation even though you correct it at the sensor you don't really know the angle at which the web is approaching and that can cause what is called as waves downstream again if you you won't have good guiding performance if you have wrinkles I mean if the web is wrinkling that is going to cost the edge to move back and forth there's no way that you can have good guiding performance with that or edge girl or flutter or sometimes plane change can also have that effect if you have large magnitude later and your stroke of the actuator is limited or the correction that the WebKit can provide is limited then you can expect good guiding performance whenever the actuator pops out on either side of its stroke again if you use a lower bandwidth actuator and you have a higher frequency error you can expect good guiding performances and sensor if you don't have a good sensor or if it has gain changes then you can expect good guiding performance and then improper installation can actually amplify the error so that's another thing that we can't expect anyway so just to summarize the factors affecting we talked about a machine related process related material related and the web guide related which is like the stroke deadband actuator backlash correction stroke limit and things like that so in terms of design requirement a good knowledge of the conditions like web speed location thickness stiffness environment tension desired correction all of these are important for us to have a good well-designed web guide and then obviously if you have a good understanding of all of these we will do well I know we're running out of time this is my last slide and I just wanted to bring this up to summarize it just to summarize our fundamentals of web guiding well web's machines process nothing is going to be perfect so we do mostly we need web guides to correct for it most of the web guiding or the the traction or the steering of the web happens because of the normal entry rule so whenever you have a misaligned roller or an out of round roll all of those things are going to affect the the disturbance created within the machine the sensors when you're installing it on a web guide we need to be installed as close as possible to the web guide and then the web guide has to be located as close to the process that needs alignment we cannot have an unwind and have a guide on the unwind and then have ten spans later you have a process where you meet see where you need the alignment we need to have the web guide right next to the process where the alignment is needed none of these action of the web guide will have any effect if we don't have traction traction is indirectly related to tension so if you don't have good tension or traction would be in the web and the roller you cannot expect good guiding performance proper installation depending upon the type of web guide we have is important and then also improper installation can actually adversely affect your material it may wrinkle the material create edge stresses or instability and finally the overall guiding performance it's actually a function of the sensor the actuator the controller even the web itself so in order to have all of those we need to have a pretty good all of these have to be pretty good that's the summary and I do have a slide which shows some additional informations on different things that we have on our website I will leave this for a quick second and I was supposed to have some polls that I was supposed to share with you but I didn't so I'm going to have a sum of these put up right now and if you can answer these questions that would be great basically we want to make sure that this webinar was useful to you or not and also know what would be something that you would be interested in in the future and what are some of the biggest problems that you see in your operation is it web guiding is attention related it's a raw material related or process quality issues okay so while I have these polls on let's see if I have anything that I have missed in the Q&A okay so there was a question about why would you want a deliberately oscillated role well there are some times where you have gage band variation that means the thickness of the web across the width of the web is different this is especially true when you are folding the web or like in shrink sleeve applications and if you guide the web at the same location the gauge band variation is going to have different stresses on the bound role so the hardness of the roll along the width of the web would be different and and that causes problems in terms of telescoping and when you transport the rolls and things like that it might have some issues so what they do is they deliberately move the web guide back and forth so that the thickness variation is evenly spread across the entire width of the roll so that's why you want to deliberately oscillate the roll back and forth these are only when when you're converting process has an intended thickness difference like when you are sealing or closing and sealing a web guide there's a question about master slave application what is that and could you give an example okay so whenever you have a lamination process you have one layer of the web that you need to laminate with respect to another layer of the web that's when it would be important to have a master slave so one layer of the web can be guided to a location and then the other layer of the web its reference or the guide point would be dynamically adjusted so that you can match those two webs together it can also be done if both these web guides are guided to the same machine reference but usually that's a problem because when you're moving the sensor you don't know if you put them exactly at the same machine reference so in that case you would have one web as a master and then the slave web guide will have its guide point changed based on the based on the master position okay so let's see got another poll here what are your biggest challenges with web guides is it the lack of performance is the complexity of setting them up or doesn't have enough features what is the biggest challenge for that for you and finally in terms of future topics what would be of interest in the future webinars we talked about fundamentals of web guiding here we didn't talk about anything related to web guiding applications like edge guiding Center guiding line guiding contrast cutting those things we didn't talk about there are advanced web guiding concepts as well are you interested in measurement and sensing technology or general web handling topics and would you be interested in training on roll-to-roll products okay so there is a question from Jay and let's see if I can allow Jay to talk oops that went away okay there we go okay Jay I think your microphone should be enabled Jade okay well hopefully we were able to give you a little bit about the fundamentals of web guiding and let's see if and show some of the results here Oh anyway thank you so much for your time this afternoon and thank you for giving us an opportunity to talk a little more web guiding and web guiding fundamentals I have put our contact information there if you have any other questions please let us know either by email or calling us that we have this webinar recorded and now what we could do is it will share the video of the webinar in a follow-up email and if nobody else has any other questions we would stop the session and appreciate your time thank you everyone have a good day

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# Web Guiding System Data Collection and Analysis

URL: https://r2r.tech/videos/web-guiding-system-data-collection-and-analysis.md

At Roll-2-Roll Technologies we want to offer you the best products possible. We do extensive research and testing to optimize our web guiding technology. Check out this video to see how we collect data on our web guides. 

## Transcript

Hi, this is Pedro Velasco with Roll-2-Roll Technologies. Our products are based on our own research. Every so often we'll go back and do some more testing and we do some further investigations of our products work. In this case, I want to show you this is one of test benches.

We build this on our own. Right now, we're actually doing some some data collection on our newest web guide, which is the compact low profile Displacement guide and what we're trying to do right now is we're putting in a disturbance upstream sinusoidal disturbance and then we're recording comparing what the material coming in, how it's coming in and compare with the material coming out, the result of correction through our web guide. We take all that data and then we do some comparisons and make some corrections and further improve the way our systems work. So right now, we're showing you the downstream side of a web guide and what we're doing is the sensor on this sensor here is actually reporting the information from the data at the position of the web guide and of course our web guide is being controlled or guided thanks to that sensor that we have over there, which is a sensor that's provided with the web guide.

As you can see from this view we can see the sinusoidal disturbance being caused by one of our web guides on the front through programs that have to do that for us and then downstream closer to the camera, you can see the our featured web guide doing the correction. Now one of the features our controls is they learn on their own. And that's part of our algorithm So we take the information from this and we further correct it. also allows us to create other features for our customers such as the KOIOS data analytics which can actually help predict other problems upstream from where the web just based on information that are systems provide.

You can see more of the information our web guides at www.r2r-tech.com

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# Web guiding system installation

URL: https://r2r.tech/videos/web-guiding-system-installation.md

Roll-2-Roll Technologies shows just how easy it to set up its web guiding system. The automatic function does all the work, so you don't have to. Just press the automatic button and let it roll.  

## Transcript

As a real plug-and-play system, ARIS adapts to any material, requires no calibration, and very little set-up time. First plug in the sensor to the 12 prong outlet in the back of the machine, using the guide notch that aligns the plug to the outlet. Once the sensor is plugged in, tighten the lock collar to hold the sensor cord in place. Slide the sensor into the sensor guide rail.

Make sure the middle of the sensor is aligned with the material’s edge. Once connected to a 24 volt power supply, the user operator interface featuring language independent icons will come. A green sensor indicator will verify an operable sensor. Above the icons you will see the material edge, position indicator, represented by a green and red bars.

When the material is in correct position, you will see one red bar and one green bar. If it's incorrectly placed, you will either see no green bar or red bars on both sides of the green. Once the sensor has been aligned with web, secure the sensor using the thumb screws. When the screen turns on, the automatic/manual icon will indicating the guides last operating condition.

A green icon indicates the guide is in automatic operation. A red icon indicates the guide is in manual operation. The operator can change the condition by pressing the icon once. ARIS does most of the work through its automatic option, so press the icon to set to green and let it roll.

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# Web Guiding System Installation - Key Techniques and Considerations

URL: https://r2r.tech/videos/web-guiding-system-installation-key-techniques-and-considerations.md

This video, part of the Web Guiding Fundamentals webinar series, focuses on the proper installation techniques for web guiding systems. It covers essential elements such as maintaining a 90-degree wrap at the entry and exit of rollers, recommended span lengths, and the ideal positioning of sensors for optimal control and stability. Key considerations include sensor placement within the first half of the exit span, ensuring the plane of motion of the carriage is perpendicular to the spans, and the implications of bending and steering effects on web stability. Learn how to achieve precise web guiding with expert insights on sensor and roller configurations.

00:00 Introduction to Web Guide Installation
00:25 Sensor Placement and Span Length Considerations
00:54 Carriage Motion and Correction Mechanisms
01:35 Multiple Roller Configurations and Flexibility
01:45 Guiding Action and Sensor Proximity
02:37 Avoiding Common Installation Mistakes

## Transcript

[Music] So in terms of installation, we want to make sure that we have a 90° wrap at the entry and exit of the roller. And then there are considerations on the span length at the entry and exit. Usually you can get away with half a web width. We recommend about one to two web widths if possible.

If you have a stiffer web like metals, you might need a longer entry and exit span. We want to locate the sensor as close as possible. This is true for any web guide. It doesn't matter if it's a displacement guide, unwind guide, rewind guide, any web guide.

We want to have the sensor as close as possible hitting the span where the guiding action takes place. The recommendation is to be within the first half of the exit span. And then how long this span really depends upon how much correction you're looking for. Typically these carriages are allowed to pivot only about 5 to 10°.

If you want larger correction then you can make these fans longer. The main thing is that you need to make sure that the plane of motion of the carriage is perpendicular to the entry and exit span so that you can create a pure twist on these spans. And then as long as these rollers are moving in tandem or parallel to each other, then you will have the desired effect. They don't have to be on the same carriage.

They can be on different carriages as long as we are able to move them parallel to each other. You can even have a process here. You don't really have to have just two rollers. You can have multiple rollers.

So, it provides a lot of flexibility here. The guiding action is actually happening in the exit span. We don't want to install the sensor too far away or in the next span. This is mainly for control system purposes.

and stability. When the web guide makes a corrective action, that action is not seen at the sensor immediately. So, if you're running really fast, you might get away with moving these sensors a little farther down. But if you're running slow, whenever this web guide moves here, you would see that motion if the sensor is as close to the exit roller as possible.

If you install it here or here, especially when the web stops and there is a small error, the web guide would keep moving and that might cause the web to break or have unintended consequences. So, we don't want to have the sensor farther away or in an expand. And we don't even we don't also want to have a scenario where you have an angle that is not 90°. If you have a 90° wrap, you have twist.

As soon as you introduce something which is deviating more from the 90° you start creating bending in the web. So these kind of bending is going to act as under steering the web. It's going to cause bending that's going to under steer the web and it also causes distortions and guide instability. So we don't really want to have any of these conditions.

On the contrary, if you have a span exit span that is spread out like this, this is going to over steer the web, it's the bending effect that is causing that. And we really don't want to do that. So, ideal scenario would be to have a 90° wrap in and out. [Music]

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# Web Width Measurement and Monitoring System

URL: https://r2r.tech/videos/web-width-measurement-and-monitoring-system.md

Web width measurement and monitoring of a web within a clear web. The customer requested a system that would monitor the width of the green web within a clear web and provide a read out of the measurement, a minimum and maximum width variation set point, recording of the data and a signal when the width was out of specification to have a printer mark the defective width section of the web. The application uses WPS 221 WL sensors for contrast sensing. The signal is processed by the SCU5 D(E)C with Ethernet Communication Capability and a PLC RTI 3.5. Price comparison, thousands of dollars less than the previous system they had mounted.

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# Web Width Measurement Sensor

URL: https://r2r.tech/videos/web-width-measurement-sensor.md

Web width measurement is a common need in the converting industry. This video shows the web width measurement application with the WPS.

## Transcript

Hi, this is Pedro Velasco with Roll-2-Roll Technologies. Today we talk a little bit as things that we can do with our sensors. Now our web guides are capable of doing edge guiding or center guiding with just a touch of an icon and that is because of our sensor technology. Now our sensors on their own they can actually have many other features that deal with that application.

For example this 221 mm sensor, we can use it to monitor the width of any material that is within the 221 millimeter sensing window. In this case they can measure the width, it can also detect that there are differences in the width and therefore send out a signal to tell you that there's something wrong with it. Now we can also do that, let's say that the sensing the material is wider than the sensing window. Well we can also use two sensors we can use two 221 mm or 2 48 mm and then hook them up to our sensor control unit and keep on doing that same application which is measuring the web width or at the same time controlling or monitoring the web width in case you want to make sure that the material is within specs in width wise.

This can be done with any of our sensors. This can be done with our 221 millimeter sensor the WPS 221 IR or this can be done with our 48. There are 16 mm sensors too and also with our new sensor the 440. Now this is some of the features that we have and we will talk some more about other features in future videos Thank you very much

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# Web width measurement with ARIS web position sensor

URL: https://r2r.tech/videos/web-width-measurement-aris-web-position-sensor.md

Web width measurement with ARIS web position sensor from Roll-2-Roll Technologies is shown in this video. The capabilities of the sensor include both web width measurement and monitoring. 

## Transcript

Roll-2-Roll Technologies adds width measurement to its ARIS line of products. Absolute or relative web width can be measured based on the sensor configuration. With two output options the user has the flexibility to monitor the width based on their need. The real-time measurement can be output as an analog voltage between 0 to 10 Volts.

As the width changes the analog output increases or decreases proportionally. In this video absolute web width is measured using ARIS WPS 221 a 221 mm wide sensor. A 7 volt output corresponds to 70% width coverage which is equal to approximately 6 inches. The analog width measurement option can be used for quality monitoring and real-time control of web width in extrusion processes.

For low modulus webs, the width measurement can also be used to monitor necking in the web. The digital output option allows the user to set pass/fail conditions based on web width. A low and a high limit for width tolerance can be set. The resolution of the tolerance is in millimeters.

If the actual measurement is within the negative and positive width tolerance the voltage will be zero; this corresponds to a pass condition. If the width goes below the lower limit the output will be a negative voltage. A non-zero voltage is a fail condition. Similarly if the with goes above the upper limit the output is a positive voltage.

This pass/fail condition can be used for a variety of quality control purposes. For wider webs two sensors can be used for relative width monitoring. In that case the analog output corresponds to the percentage of web covering the two sensors. The absolute width of the web can be obtained based on the physical distance between the two sensors.

For more information please contact us.

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# Web Width Measurement with Roll-2-Roll WPS 440 Sensor

URL: https://r2r.tech/videos/web-width-measurement-roll-2-roll-wps-440-sensor.md

Roll-2-Roll Technologies offers robust width measurement capabilities with the WPS 440 Sensor. Using a PLC  connected via ethernet, we are able to accurately measure the width of any material. 



This is just one of the many capabilities that our WPS 440 sensor can provide. The Roll-2-Roll Technologies ARIS WPS 440 is a versatile sensor with an integrated sensor control unit, a 440 mm sensing window, and multiple functionality. The sensor technology requires no setup or calibration. The sensing principle relies on light scattering and spatial filtering properties of fiber optics to accurately determine the features on the web. The 440 mm sensor version is suited for edge guiding applications with frequent width changes, web width measurement, center guiding, etc. The sensor is also used in simple inspection applications such as thread counting, string coverage, void detection, etc.



The patented fiber optic sensing principle enables the plug-and-play sensor technology. The sensor technology adjusts automatically to the physical characteristics of the material and provides an accurate position measurement. ARIS WPS is essentially an affordable vision based sensing system different web sensing applications.



For more information visit: [https://r2r.tech/products/aris-wps-440](https://r2r.tech/products/aris-wps-440)

## Transcript

well today we just want to show a little bit more about our width measurement application with our 440 sensor so we have the 440 sensor installed and then you have the web coming over it we have installed two support rollers so that when the web moves it doesn't flutter too much we want to avoid fluttering whenever we do web width measurement this sensor is actually connected to Ethernet IP so you can connect it to a a PLC like this or we also have a web browser interface on the computer that you can connect to so the main things are here is how far the sensor is from the web right now we have installed it at about 5 millimeters from there that's the optimal distance that we recommend the sensor is installed facing up that is good but just to avoid any dust and other accumulation it may be better off to face the sensor down so that it's looking down towards the web a few other things that we need to consider is the the the free space behind the sensor we want to maintain about six inches of free space so that nothing in the background is seen by the sensor that's the optimal way in which we can get the best results there's also a way for us to get the maximum scattering out of the sensor if you want to do that what we would do is we will raise up this roller so that the web comes at an angle now about 10 15 to 20 degrees is the angle that we want and it depends upon the orientation of the sensor so if we if you want to get the maximum scrap scattering what we will do is we will raise up this roller so that the web comes this way but those are the few things that you want to consider before installing our 444 width measurement application other things to consider is this free span doesn't have any twisting so we don't want to install the sensor right next to a dancer roller or right next to a web guide we want to install the sensor between two fixed rollers so that we have a fixed pan and then web doesn't flutter that will be the ideal scenario what we were going to show right now is how do we get this up and running right now as you can see we have the power on to the sensor it's connected to Ethernet IP right now it's connected to a network device like a router or a switch so you can connect to the sensor through the network if you don't want to do that you can directly connect the sensor to the computer or you can directly connect this to your PLC or our PLC for that matter so just for demonstration purposes we're going to connect it to both the computer and the PLC to a network the next thing that we want to do is to connect the sensor to the PLC one of the first things that we want to do is find the IP address once the sensor is connected and powered up and connected to your network device we can pull up a utility called IP config we have information about that on our website we can go once you open up open up open up that program it will show what device there is and what's the IP address of that right now the device is said to have DHCP set automatically and it has an IP address 0 dot 0 dot 0 this is happening mainly because the Gateway doesn't match so what we would do is to make sure that they get the Gateway matches let's do that the Gateway is one one sixty eight dot one dot one and AP address of this device so right click configure on my parents one point something see you so once we do that we set a static IP address with the Gateway and everything now we can right-click and pull up a web browser and that's going to bring up our dashboard so this dashboard basically shows us several things the web measurement is shown here so this is the web in that the width measurement is 155 and something millimeters we also have a filtered width measurement we have a filtering algorithm that would take the filtered value of the raw measurement and then edge location which is left edge so that's saying where this edge is and then the right edge is showing where the other edge is and then within our software we also have what we call it as a quality factor which is basically think of it as how good of an image or how good of an edge that is so it says that the left edge has a quality factor of 300 and something and the right hand has a quality factor of 100 and something so this is a easy and quick and easy way to test our sensor make sure everything works fine we have a plot that shows the weight the measurement we also have other things that we can do with the sensor in terms of adjusting the brightness all of these are shown here so the idea the main thing that we want to do is make sure that the quality factor on the both edges are pretty high and as we mentioned before one of the things that improves the scattering is angling the sensor either we can lift this roller up or angle the sensor so that we get a pretty good quality factor so if you can notice when I move that since we don't get a good scattering the quality factor went down but if we install the sensor at the right about 15 degrees angle then we get a pretty good quality factor signal and then you get the measurement there so this particular web browser interface allows you to pan the data plot the data you can also save the data if you click on the save it stores that data as an excel file with all the information that we collect which is shown here such as the brightness and and the edge position and the width and everything so that's basically about the the web browser interface as you can see we can run the web and it collects the data as the web is moving over the sensor let's move on to the PLC and kind of show you how we can set up that PLC this is a special software that we install on it basically for customers who doesn't want to set up their own system they have the ability to use our PLC that we supply to do width measurement and also have the ability to provide a trigger measurement whenever the width varies so one of the first things that we want to do to get the PLC communicate with the sensor is to tell the PLC what the IP address of the sensor is in order to do that we're going to press these corners one after the other and then go to offline and this shows up the main screen here in the offline menu we click on peripheral and within the peripheral we're gonna select Device slash PLC setting and here we're going to use the ethernet/ip explicit messaging protocol so that's the one that we're going to select and then these settings are fine which is the standard setting the main thing that we want to set is the IP address of the device so we're going to go click on device and then set the IP address so right now it's set to 192 168 1 8 so our sensor IP address that we manually set was 192 168 1 dot 100 so we're gonna type in 100 enter and exit and then Save Changes so now the PLC is going to reboot with the new IP address we just have one more step to do to connect the PLC to the sensor or connect the PLC to communicate with the sensor and that's to enable the Ethernet communication so in order to do that we're gonna go into the settings and communication and turn on internet might be once we do that now we got the measurement from the sensor so this is the real-time width from the sensor that is going here now if the customer wants to set a few things for example if they want to teach the sensor so that we want to avoid any inaccuracy in accuracies in the measurement what we will do is we will put the web where at the location where they desire it and measure the width of the web then let's say in this case it's 155 millimetres would go in and press this 155 and press record width now they can also set warning and alarm ranges so for example we want to say alarm is for 4 millimeters warning is for 1 millimetre and going so as long as the width is within that range which is 155 we taught the sensor for that width it'll show green and whenever the width goes about a millimeter high or low the amber would show up and then when it goes about the warning the red would show up so and that's pretty much it right now we're seeing the weight variation because of the curls and all these things in the web we're trying to show or simulate some of the things that you would see when the weight varies by these curling there's also an ability for the customer to set recipes so if they have different product with you can set what is the nominal weight what is the alarm weight what is the warning with things like that you can load them you can save them and so on and so forth and also there's an ability to connect a USB here directly and save the data through the USB on this PLC right here and this PLC can be connected to an signal alarm signal lighting system with green amber and red so that it's readily visible for the operator running the machine so that's pretty much our width measurement system using our WPS 440 sensor you

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# Web Width Measurement with Roll-2-Roll® Controller: RTI and SCU5

URL: https://r2r.tech/videos/web-width-measurement-roll-2-rollr-controller-rti-and-scu5.md

In this video we discuss in detail the setps involved in logging the width measurement from SCU5 using the RTI.

## Transcript

hello everyone today we are going to talk a little bit about the web width measurement application and how we can use the scu5 controller to measure the web width and also use another plc to collect that data log that data and also save it in a csv file on a usb thumb drive in order to do this what we're going to do is we're going to first set up our se5 controller for width measurement mode and then we also offer the rti which is the plc which has a special program that would actually talk to the scu5 controller and then allow the user to connect a usb drive to the plc so that the data can be logged automatically in the plc and the communication between the plc and the sco5 controller is being done through ethernet ip and then the user also has the ability to set up lot numbers so that when they are tracking different product codes they can enter that and that information is saved in the usb file automatically and the plc also allows the user to start and stop the data collection based on a line signal so that the data is only collected when the web is running and when it's not running the data can be automatically stopped from data collection and then finally we can also connect that plc to a stack light directly so that we can provide the alarms for warning error and then all good signals so all of this can be done uh through the plc and that's what is shown here this is the plc that we would be using to do that the first step in this process is to make sure that we have the suv5 controller set up for web width measurement mode and then the second step is to make sure that the ethernet settings on the sc 5 controller and the plc matches and then the third step is basically setting up the parameters on the plc so that you have everything for triggering the stack light as well as data logging so those are the three main things that we are going to cover so first we'll start off with setting up the se5 controller for width measurement mode as you can see here we have the sco5 controller now ready and then we also have the two sensors up on the top right corner and we're using two sensors one for detecting each edge of the web we'll go through this process so that we can set up the controller for width measurement as you can see if a web is presented you can see that both edges of the web are seen by the two sensors and then once that is there we just need to set the controller for width measurement mode and that can be done by following these steps first we're going to go into the tools icon right here and then go on the bottom power user and then go into the analog mode and make sure that the width is selected here and when we select this as the width now the home screen now shows the width as the output the controller still doesn't know the distance between the two sensors so in order for us to do that we need to teach the controller for the width so if i present the web here it's going to give some random values there so in order for us to teach that the distance between the two sensors we're going to go into the tool cycle and again and then the top right icon is the operator icon we're going to click on that and we're going to click on the width mode and then a few things that we are going to set so that we can teach the controller for the right measuring mode first of all the output type we're going to change it to absolute and then the nominal width this is going to be the width of the product that you're going to present while you're teaching so in this case the width of the product is approximately about 5 inches so i'm going to set in 5 inches right there and you can use this icon to change that and then the upper limit and lower limit it does not matter for this application because we're going to use the data raw data through ethernet to take care of that so we don't have to worry about that and now at this point all that we have to do is to present the web and then teach that while the web is presented so that's what i'm going to do right now so once we present the web and the teaching is accepted now we can go back to the home screen and now the controller is set up for width mode with two sensors and then now it's showing you the absolute width of the product as we move the web when the weight changes you can see that the width of the product also changes so the next the second step is that now the data is being collected in the scu5 the data is sent through the ethernet it's not being logged so in order for us to log that data we need to be able to set up the network parameters so that we can take care of these so the second step is to make sure that the network parameters are set up the easiest way for us to find out what is the ip address of our device and also set the network parameters is through the operator interface directly so we can do that by going into the tools icon the power user icon and then go into the communication we want to make sure that the ethernet is on as shown here and depending upon your network settings you may or may not want to have the dhcp on and then ftp on that really doesn't matter for this application if a network device is present then the controller will actually show the type of industrial network that is here and this is called ethernet ip and for in our case ethernet ip is the type of industrial network that we are using depending upon the firmware version you might have something here that says what type of module that we have we have two types of modules hms as well as hillshare depending upon what module you have that will show up if you have a older version of the firmware let's say version 3.6 d or maybe even 3.6 a then the type of module will not show up there the ip address of the module is shown here the subnet mask is shown here the gateway is shown here and then the mac address is shown here if you want to change the ip address of this module then you can just press this ip button and then type in the ip address that you want to change so i'm going to say 192 0 0 and 1 100. this is just for illustration purposes i actually put it as 2.100 if you want to set this you can press the set button to set it because i set the ip address wrong so i'm going to go back in and put the right at the address so again press on that one ninety two one sixty eight zero zero one and one hundred once we do that we need to press the set at the address to have the ip address set based on what you have entered and then if the ip address is different than what you had before you can hit the refresh button just to be sure that the controller has taken the ap address in some of the cases we might have to restart the whole controller especially with older firmware we might have to anytime we make a network change we might have to restart the power cycle the call controller with the newer firmware and the chip that we have we don't have to do that but likewise you can do the same thing for the mask and gateway and then if you have a controller or network where you are setting the dhcp then you would turn on the dhcp and anytime you turn on or off the dhcp you do need to power cycle the controller but essentially that's the easiest way for us to set the ip address the network information and also to view what controller or what module that we have on this particular controller there's also ways in which we can set these network information through a computer we're not going to talk about it today but this is the easiest way in which we can set this up now the second step in in this process is once we have this set up now we're going to go to the plc and make sure that the plc has the right parameters for communicating between the seo 5 and this controller the easiest way to make sure what the plc network information is and what the ip address for the plc is is done by actually pressing on the top left and the sorry the bottom left and the top right corner of the plc several times okay once you have that then you can go in and click on the offline so once you get into this offline mode you can also ensure that the ip address for the plc is set properly and make sure that it matches with the network information on the su-5 controller you have the ability to connect the suv5 controller to a managed or unmanaged network likewise you can do the same thing with the plc or you can directly connect the plc to the sc 5 controller without going through a switch if you do that what we need to make sure is that the network information on the plc matches the network information on the sco5 controller and then plc has a distinct ip address compared to the sco5 controller and then the plc also knows the explicit ip address of the seo 5 controller so in order to check all of these things what we can do is we can go into the offline mode as shown here once you are in this offline mode we can go into the main unit and then click on the ethernet and then click on the lan and now this shows the information for this plc so this is the ip address subnet gateway for this plc we just need to make sure that this information is similar to the information on the scu5 controller so let's go ahead and look at that c5 controller communication and the ip address for the se5 controller is not the same as the plc which is what we want the subnet mask matches the gateway matches and then if you compare that with the plc has an ip address of 10 the sg5 has an ip address of 100. so once that is done we can go back into the peripherals and then look at the device plc settings ethernet ip and then go into that device and this is actually the device that we are trying to connect in our case scu5 so that ip address of that u5 matches the ip address on the plc now we have set up the plc and the se5 with the right network information so that they can talk to each other okay once we have all the ap address set up now we need to go into the steps that are necessary for data logging and also to start the communication first and foremost what we want to do is we want to make sure that the communication between the plc and the sg5 controller is going properly and for that we're going to go into that communication screen and then right now it says the ethernet ip is actually off so let's go ahead and turn it on now the ethernet ip is on if you don't see any error messages then it means that the sg5 controller and the plc is communicating properly just to show you what happens if it doesn't communicate i'm going to remove the ethernet connection from the se5 and you can see that there will be an error message that will show up saying that the tcp connection is lost or things like that so if you see that error message that means that the either the device is not set up properly to communicate with the seo 5 controller and this would be the error message that you would see um and it shows that that's not the plc it's basically it's not able to connect to the sco5 controller so as soon as we connect the cable back this error should disappear within a few within a minute or so and then yeah likewise now it's communicating with the plc with the suv so once that is set up so when you have a web in front now this should provide you the width of the web on the plc but it's also showing that width on the su-5 controller so in order to change the units what we are going to do is actually go into the setup screen and then go into the other setup as well and then the units are here you can set that to inches even though scu5 may be set to inches the plc can be set to another unit irrespective of what the unit of the scu5 is and in this screen you can also change the language currently we support english and spanish so if you press spanish it's going to go to all the icons would change to spanish and then if you want to set things back to english then you can do that so this is where you would set the units and you can go back to the home screen and now if we present the web now the units would be in inches just like what the sc5 is now we know that the sco5 is communicating with the plc and then you are able to see the data now we can add more things to it so as you can see on the home screen there are the three lights that are available these are the three digital outputs so in order for us to run up a stack light what we do is we take the data from the scu5 and then use the recipe or the settings that are there on the plc so that you can set up upper limit and lower limits for the alarms and warnings that way you can connect it to a stack light and the stack light would go on based on that so in order to do that we're going to go into this screen and then go into the width setup and we can set the upper limit and lower limit for the alarms and all the units are going to be in the respective units for the alarm and as well as the width so the first step that we want to do when we are in this which setup screen to trigger the stack light is to set up the nominal width the alarm warning and all this information so in our case we have set the nominal width to 5 inches but if you want to change it to some other value you can just press that button upper limit and lower limits for the alarm and the warning doesn't have to be symmetrical so it can be asymmetric the alarm value should always be greater than the warning value uh that's the precondition when the width value exceeds the alarm value or goes above the upper limit of the alarm value or goes below the lower limit of the alarm value then the red light is going to be indicated and then likewise if it's in the range for the warning it will be in the amber and then if it is within the nominal width that's going to show the um essentially the green so once we have it set up we can go to the home screen you can see that right now the alarm is enabled and then when the width is within the nominal range you have it as green and then if the width changes to some value that is outside those limits amber and then if it's really off then it goes to red and that's the way in which this works now you can also plot this data so you can see that in a real time graph it's going to show you the the limits for the width as well as the limits for the alarm showing that in red so you can have a visual indication of how it's been doing starting with the graph like that now that we have set up these alarms and warnings and stuff like these are not used for data logging purposes but these are just for triggering out triggering the stack in order to lock the data you can start logging by connecting a usb and if you want to have some lot information you can go in and press that and enter your lot number so that when we log the data that lot number is also allocated there so in order to log the data we need to be able to connect the thumb drive there's a usb port underneath the plc that we can use to connect that thumb drive so i have an extension cable here so i'm going to connect the thumb thumb drive through an extension cable but as soon as we connect that thumb drive to the plc there should be a blue icon that appears in the bottom right as you can see in the bottom right hand corner that icon appears and if you want to take a look at it go inside right now it has disappeared but that lets you know that the usb has been recognized and connected to the device once you are ready with that what we can do is go into the plc and start data logging so we have the web here and we have presented all the uh the settings for the upper limit and lower limit and all those kind of things so since they're all set up right now we can go ahead and start collecting the data and when the web is there you can see that it's measuring that we're going to go away and then communication data log now it's saying no data logging is being done so in order for us to do the data logging i'm going to start and now this is started data logging the remote data log is off right now but if you want to have a another interface or a signal that would tell us when to lock the data i went to start i'm going to stop then you're going to enable that if you want the operator to start and stop the data logging then you can just go here and do it since the logging is being done it says logging data on the top left hand corner and then once you're done data logging you can just press the stop button right there and then if you want to remove the usb you can safely remove the usb by pressing the top and the bottom just like what we did before and then now it shows up the usb icon at the bottom there so we're going to click on that icon and then say remove usb storage device and press yes on it and then the storage device has been removed successfully because that icon on here has disappeared now you are able to disconnect the usb thumb drive and once you connect it to the computer then you have the ability to take a look at the data so let's do that next okay we're going to switch over to the computer screen now the usb is connected and you can see that the thumb drive has been recognized and it shows the different files that are there so today is the 25th so we have that file right there showing the 25th and if you double click on that file you can see that it has collected the data the lot number has been assigned and then you also have the sorry about that you also have the width data that is being presented here as you scroll down okay as you scroll down you can see the actual width measurement that was done so right now the time scale is about in this particular program it's about once per second so the width at that time was 4.735 inches and the units is basically the same units that we have on the controller so if you had units the unit shows up and if you have inches it shows up the lot number shows up and then the time when it was recorded and then the date when it was recorded so that's as simple as that to be able to log the data through the rti plc um in from our scu5 controller one other feature that we have is that we also have the ability to provide some recipes the recipes are used when you are running different web with products and you don't want to change the nominal with the alarm and the warning information every time you change the width you can create your own recipes and that's done here and um anytime you want to load a recipe you click on that product product number and then you're going to press load recipe and whatever that value is going to be loaded it's going to be displayed it will not be presented or pushed to the home screen until you press the accept so now once you press the accept that value is being loaded anytime you want to save a new recipe you're going to go in there press on load and then press the values for those so if i want to change that nominal width to 5 inches i'm going to enter that nominal width and then the all the other settings are set now i am happy with this recipe so what i'm going to do is i'm going to save that now product one every time we go to product one it's gonna have the five inches so we go back to product two load that recipe that shows up there and product one come back here and load that recipe now it's five this is just displaying it so if you want to push this to the home screen you still need to press accept and we're gonna do that now if you go back to the home screen that's gonna show you that the new alarm and warning signals and you can see that here if i present the web you can see that it's good now and it's an alarm now i think so that's essentially it

---

# Web Width Measurement with SCU5 Controller: Digital Output to Drive Stack Light

URL: https://r2r.tech/videos/web-width-measurement-scu5-controller-digital-output-drive-stack-light.md

Web Width Measurement with SCU5 Controller: Digital Output to Drive Stack Light

## Transcript

hello everyone this is arvind say shadri from Roll to roll Technologies today I'm here to talk a little bit about our width measurement system with the digital output we have a demo set up here where we have two sensors the odc48 set up for width measurement application and that was going to provide a digital output and we have a stack light in the back and that's going to provide an output based on whether it is within range or not in order to do that let's go ahead and first set up a few things I'm going to go into the tools icon here power user and make sure that both sensors are enabled one is set to left the other one is set to right and then can go in and make sure that the image that we are looking at is good Sensor One image is good Sensor 2 image is good make sure that both the brightness are frozen take a look at our previous videos for more information on how to set these things up both sensors are in Edge mode and now we are pretty much ready to go go and enable the width output so analog and if you set that mode to be width then you should be able to see that now we can go in and teach the system for the width of the web in this particular case the width of the web is six inches so I'm going to go in and set that up to six inches oh six right there okay and then I can do the teaching so I can teach and accept and now we have set up the width and basically what we did was we taught the two sensors or we thought the controller the distance between the two sensors based on the web that we already have and we also have the upper limit and lower limit for the alarm signal and if we press this then we have the warning signal we have the upper limit and the lower limit for the warning signal as well so we can set up both of these and once that is done we can either choose the output is relative or absolute and if you press relative then the screen is going to show just the change in width and then if you have it absolute it's going to show you the actual width itself let's go to the home screen and you can see that it's in relatives because we taught the sensor right now everything is fine we do have this threaded up with the web that has some width changes so one of the things that we are doing is that the same sensors that are used for width measurement are also used for guiding this is applicable as long as you don't have too much plane change in your guiding application so what we're going to do is we're going to turn it in auto start the web guide and let it run so this is showing the the real time with change but as you can see in this stack light right here when the width changes from there's the Green in the bottom and then Amber and red showing that as the width goes above or below those warning limits or alarm limits the output is going to turn on really simple system for width monitoring and like I said it can also be done with guiding at the same time for more information about our products and different application visit our website and subscribe to our Channel thank you

---

# What are Displacement Web Guides?   Principles and Applications

URL: https://r2r.tech/videos/what-are-displacement-web-guides-principles-and-applications.md

Displacement Web Guides: Principles and Applications

In this episode of the webinar series 'Web Guiding Fundamentals,' we delve into the intricacies of displacement web guides, a widely used and recommended solution for web guiding applications. Learn how these guides work without bending the web, their design principles, and why they are considered 'perfect web guides' with a one-to-one ratio of movement. Discover the importance of entry and exit roller alignment, and understand the difference between displacement and offset pivot guides.

00:00 Introduction to Intermediate Web Guides
00:02 Understanding Displacement Web Guides
00:17 Mechanics of Displacement Web Guides
01:08 Design Principles and Benefits
01:26 Addressing Common Questions
01:59 Importance of Twist in Web Guides

## Transcript

Now moving over to intermediate web guides, we have a displacement web guide. This is another type of one of the most commonly used web guide that you're going to see and we would recommend this as the first choice for any web guiding application. One of the main reasons for that is it actually displaces the web. And in this web guide, it's not bending the web.

The reason why it's not bending the web is you have this entry span and a 90° wrap. And then you have the plane of the carriage right here. When this carriage pivots, the pivot point is shown here, but that's a mistake. It should have been right at the edge of right here.

So when this carriage rotates, pivots about the pivot point at this point right there, these two rollers are actually moving in tandem. So there's no bending in this region. In these fans, since they are perpendicular, that motion is a pure twist. So really there is no bending in this kind of a web guide.

If the web guide is designed properly, then these web guides can have one one ratio in the sense that if you move the web guide one unit, then the web will actually move one unit. That's why we call them a perfect web guide. I do see a question here that says, would you agree that an offset pivot guide acts on a different principle other than normal entry? That is correct.

Because these two rollers are parallel to each other. There is no bending in the span. The entry and the exit rollers are perpendicular or the wrap angle are perpendicular. This span is perpendicular to the plane of motion of the web guide.

They are going to be in twist. So there's no bending. And when there's no bending, there's no normal entry coming into picture there. The twist is an important design part.

And this would be our first choice for us in terms of applying it in any webg guiding situation.

---

# What are the Components of a Web Guide

URL: https://r2r.tech/videos/what-are-components-web-guide.md

In this educational video, we delve into the fundamentals of web guiding systems, essential for the Converting Industry. We'll explore four key components of a web guide: the guide structure or mechanism, the actuator, the sensor, and the controller. Learn how each element works together in a closed loop feedback control system to ensure precise web positioning. Ideal for industry professionals seeking to enhance their understanding of advanced web handling technologies.

00:00 Introduction to Basic Web Guiding Systems
00:17 Guide Structure and Mechanism
00:34 Role of the Actuator
00:52 Importance of the Sensor
01:09 Function of the Controller
01:27 Schematic Overview of Web Guiding Components
01:56 Closed Loop Feedback Control System

## Transcript

In terms of a basic web guiding system, we are mainly dealing with four main items apart from the web. One is the guide structure or mechanism. This is the device that is actually making contact with the web and that's the one that is need to be moved or it moves the web. There are different types of guide structures that we will go through.

The other component of a web guiding system is an actuator. So actuator is something that takes an electrical signal and converts that into physical motion so that it moves the guide structure so that the web can be located at the desired location. The third and one of the most important components of a web guiding system is a sensor. The sensor is the device that provides the feedback.

The sensor is the one that tells us where the web is inferring the position and then that signal is sent to a controller. The controller is mainly the intelligence or the brains that takes that sensor signal and computes the corrective action required. So the actuator can move the guide mechanism to the the location where we can get the desired web position. Again, another schematic of how the components of the web guides are.

Web is a part of the web guiding system. And then you have the mechanism. There's an actuator inside the mechanism. The sensor gets the position feedback of where the web is, sends that information to the controller.

controller then computes an error and it sends the command to the actuator so that the mechanism can be moved to position the web at the right location. This is a closed loop feedback control system that is a main part of a web guiding system.

---

# What are the Components of a Web Guide System?

URL: https://r2r.tech/videos/what-are-components-web-guide-system.md

Understanding the Key Components of a Basic Web Guide System

In this episode, we delve into the essential elements of a basic web guide system. We explore the four main components: the guide structure or mechanism, the actuator, the sensor, and the controller. Learn how each component plays a crucial role in ensuring precise web positioning, from making physical contact with the web to providing feedback and executing corrective actions in a closed-loop feedback control system.

00:00 Introduction to Basic Web Guiding Systems
00:12 Guide Structure and Mechanism
00:29 Role of Actuators in Web Guiding
00:47 Importance of Sensors in Web Guiding
01:04 Controller: The Brain of the System
01:52 Closed Loop Feedback Control System

## Transcript

In terms of a basic web guiding system, we are mainly dealing with four main items apart from the web. One is the guide structure or mechanism. This is the device that is actually making contact with the web and that's the one that is need to be moved or it moves the web. There are different types of guide structures that we will go through.

The other component of a web guiding system is an actuator. So actuator is something that takes an electrical signal and converts that into physical motion so that it moves the guide structure so that the web can be located at the desired location. The third and one of the most important components of a web guiding system is a sensor. The sensor is the device that provides the feedback.

The sensor is the one that tells us where the web is inferring the position and then that signal is sent to a controller. The controller is mainly the intelligence or the brains that takes that sensor signal and computes the corrective action required. So the actuator can move the guide mechanism to the the location where we can get the desired web position. Again, another schematic of how the components of the web guides are.

Web is a part of the web guiding system. And then you have the mechanism. There's an actuator inside the mechanism. The sensor gets the position feedback of where the web is, sends that information to the controller.

controller then computes an error and it sends the command to the actuator so that the mechanism can be moved to position the web at the right location. This is a closed loop feedback control system that is a main part of a web guiding system.

---

# Why Use Center Guiding in Converting Operations SCU6x Controller

URL: https://r2r.tech/videos/why-use-center-guiding-converting-operations-scu6x-controller.md

In this video, we explore the two main reasons for using center guiding in web handling systems, focusing on the advantages it brings when dealing with varying web widths and poor edge quality. The SCU6x Controller's advanced sensor technology allows seamless adjustments without the need to move sensors, accommodating significant width changes efficiently. This ensures high response times and minimizes wear on actuators. Additionally, for materials with irregular edges, center guiding helps average the measurements from both sides, leading to smoother edge profiles and improved roll quality. Learn how the SCU6x Controller can enhance your web handling process.

 00:00 Introduction to Center Guiding

 00:07 Advantages of Center Guiding for Width Changes

00:44 Sensor Flexibility and System Adaptability

01:11 Challenges with Older Generation Systems

01:55 Center Guiding for Irregular Edges

03:03 Conclusion: Benefits of Center Guiding
 

## Transcript

there are two main reasons why somebody would use Center guiding one is if you're changing web widths and you want to align the material to the center of the machine then Center guiding is the best option where you would place two sensors on either side and this those Those sensors are equidistance from the center line of the machine so when the web width changes you don't ever have to move the sensors and it automatically adust adjust itself because it's going to look at the left portion of the web seen by the left sensor and the right portion seen by the right sensor this is one of the common features that we have or common value proposition from our products is that our sensors can go anywhere from 48 mm up to 960 mm that means you can have a WID change of about 996 mm up to about 1920 mm without needing to move move the sensor this provides a lot of range and flexibility to be able to have a system that can adapt to Wick changes on the flight the older generation systems might have some actuators that move the sensors based on the wick change and more often than not what happens is that those actuators have their own control Loop that needs to be tuned the actuators can wear these are the actuators for the sensors that could wear over time and that creates an issue and then the response time especially when you do a WID change on the fly with those kind of systems is going to be much lower than compared to a system with a sensor that is wide enough to cover all the WID changes so that's one of the main reasons for using Center guiding is that you can do different widths without moving the sensors whenever the WID changes the second main reason why you would use Center guiding is that let's say say you have an edge especially some kind of an extruded Edge and the edge quality might not be great so before it goes into a slitter you you have an edge and the edge is not that great instead of aligning to one edge of the web in that case if you use two sensors and then use the center line position it takes the average of the left Edge and the right Edge and does the measurement that is going to be the center line measurement and it's going to guide the web to the center this is one of the biggest Advantage for using two sensors in doing this inter guiding and especially when you have irregular edges those edges variations are not going to be identical on both sides this Smooths out your edge profile and allows you to guide the web in the middle of the machine and that significantly improves the wound roll quality especially if you don't have a pretty good slit Edge so the advantage is that you are averaging based on two Edge measurements and this helps in smoothing out the edge position those are the two main reasons why you would use Center guide

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# Why we need Web Guiding in Roll-to-Roll Processes

URL: https://r2r.tech/videos/why-we-need-web-guiding-roll-roll-processes.md

This video delves into the necessity of web guiding, covering key reasons such as material imperfections, machine variations, tension control issues, and operator errors. It explains the significance of web guides at different machine locations, differentiating between intermediate and terminal guides, and uses lamination as an example to illustrate the need for precise web alignment. Join us as we explore why and where web guides are essential in the roll-to-roll process.

00:00 Introduction to Web Guiding
00:07 Reasons for Web Guiding
00:11 Material Imperfections
01:02 Machine-Related Issues
01:37 Process-Related Issues
02:02 Operator Errors
02:17 Types of Web Guides
03:02 Conclusion

## Transcript

[Music] So why do we need web guiding? Well, there are mainly four reasons why we need web guiding. First and foremost is that materials are not perfect. You might have a poorly wound roll that is not wound properly or deliberately wound roll with an oscillation on it.

And when you are trying to feed it into your rollto-roll machine, you need to guide it so that it aligns with your process. Some materials may have thickness variation like gauge band variation either during coating or forming processes especially with paper mills. Different gauge papers may track or slide differently. Splices when joining two rolls of web might be a step change or an angular misalignment.

Some materials have a natural curvature called camber. So when the materials are not perfect, that's going to have the web nist track in your machine. It could also be due to machine itself. So either you have machines with out of round rollers like a crown concave or a convexed roller.

Whenever you have a variation in the diameter of the roller, that's a problem. Or the rollers are not aligned properly with respect to each other. That could also cause the webs to misrack. You might also have tension control issues.

If you don't have enough tension, you don't have traction, then that's going to be an issue. Whenever you have acceleration or deceleration, that might also cause the web to misrack. It could also be due to processes. For example, if you have a coding process and you have uneven coding across the width of the web, that's going to cause issues with tracking.

And also some processes where you could have air intrained between the web and the roller that would cause the web to lose fraction and mistract. That could also be an issue. That's why we need web guiding. Finally, operators mainly when they are splicing the web or when they are putting a new parent roll into their roll-to-roll machine, they may not center it or put it at the right location.

That might also cause an issue and might need web guiding. So web guides are necessary at different locations of the machine because you might need alignment at different parts of the machine. That's the main thing with web guiding. You have to put a web guide in front of any process that requires web alignment.

Just to give you an example, let's say you are laminating something and you have two layers of web coming in to this lamination process. At this point you would need a web guide so that you can align this layer and this layer with respect to each other. The guides that are used within the machine are called intermediate guides or they are intermediate to the machine and the guides that are used at the entry and exit of the machines are called as terminal guides. So we're going to look at all of these in detail but that gives you an idea of why we need web guides and where we need web guides.

[Music]

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# WPS 900 Sensor

URL: https://r2r.tech/videos/wps-900-sensor.md

WPS 900 provides a sensing range of 901 mm or 35.47”. This is the widest sensing range available today in the converting industry. 



The wide range offered by WPS 900 allows converters to handle a wide variety of web widths. A one sensor application lets you handle different web widths up to 35 inches with no sensor repositioning. A two sensor application gives you the ability to handle width changes from web to web of up to 70 inches, with the same benefit of eliminating the mechanical repositioning of sensors. Mechanical sensor repositioning, whether actuated or manual, can lead to increased down time, loss of precision in your measurements, and wear and tear in your converting line.



Aside from the benefits offered by the wider sensing range, WPS 900 offers additional benefits over sensor applications provided by other manufacturers in the market. It has a five thousands of an inch or 127 micron resolution across the entire sensing range. And as the entire line of WPS Sensor Products, WPS 900 requires no calibration when faced with changes in material or environmental conditions. So, you can look at a mesh and change immediately to a non-woven, or a film without having to calibrate the sensor. Additionally, WPS 900 is capable of detecting over 250 edges, so it can monitor multiple strips or strings.

---

# You Don't Need to Calibrate Our Web Edge Sensor

URL: https://r2r.tech/videos/you-dont-need-calibrate-your-web-edge-sensor.md

Are you tired of wasting time trying to calibrate your sensor on your web guiding system? Our sensor technology allows you to get away from the old calibration needy technology and makes installing and commissioning the edge sensor a simple operation. Check out how simple and easy it is to install our sensors for edge guiding, line guiding, contrast guiding and width measurement applications of any kind of web materials.

## Transcript

Hi, this is Pedro Velasco with Roll-2-Roll Technologies. We've all seen the videos that show you how to calibrate a sensor for edge guiding purposes. It's a lengthy process, with many steps, complicated to some people to the point that we have we've seen in some converting lines the procedure posted so that the operator can follow the steps required for calibration Well, that is Old Technology. Our technology came into the market three years ago with a revolutionary way of sensing where you don't have to do any calibration.

Here we show you how easy it is to install these sensors in comparison to the old processes where you have to go through a calibration step by step. This is the ARIS SCU5 sensor control unit. It's a very simple lightweight unit that is available with a screen or without a screen depending on your needs, but it can handle up to two sensors at a time. Today we will show you how easy it is just to get our sensor into operation with the sensor with the control unit.

First, plug the sensor control unit to a 24 DC power supply I have installed a ARIS WPS 221 IR sensor which has a 221 millimeter sensing window and an infrared light source. All I'm going to do is just plug it in. Once I match the plug to the notch I can just put it in place and the ARIS SCU control unit immediately recognizes what type of sensor we have in is it a white light or an infrared sensor even the size of the sensor, so you don't have to worry about that either and we're going to set it up to edge mode right. As soon as I place the material in front the sensor it is immediately detected.

I did no calibration for this. I can even change the material and put in something that's difficult as this, which is a bubble wrap and in it detects it. Not only that, I can change it to detect a string, count the number of strings, the position of the string. These are just some of the applications.

What I wanted really to show you was that this is all you have to do in order to get our sensors into operation no calibration at all so why waste your time using old technology where you have to go through a lengthy process of calibration, when you can have this, which allows you to do all that in just a couple steps. To see more video materials on our website www.r2r-tech.com.

---

# AIMCAL R2R Conference USA 2018

URL: https://r2r.tech/events/aimcal-r2r-conference-usa-2018.md

he AIMCAL R2R Conference has been a champion of roll to roll processing, and the converting industry for many years.    If you are a newcomer to this annual event, you will see why it consistently rates high as a valuable resource for anyone who has interest in the R2R process. The conference has steadily grown by delivering solid technical programming and valuable networking opportunities to attendees. 
  

---

# Converter's Expo 2019

URL: https://r2r.tech/events/converters-expo-2019.md

Your one-stop shop for all things converting is back in 2019 with additional exhibit space! Celebrating 12 years as the only one-day expo exclusively serving the converting industry, Converters Expo is returning to the Lambeau Field Atrium on March 27-28.



Converters Expo unites converters of paper, film, plastics and nonwovens with industry buyers, specialists and suppliers.



With over 700 attendees expected, Converters Expo continues to grow. Located in the heart of the nation’s top Converting Corridor, it is the place to find manufacturing partners, check out testing and prototyping equipment, meet with producers of disposables and learn the latest in flexo printing and packaging.

---

# Converters Expo 2018 - April 18, 2018

URL: https://r2r.tech/events/converters-expo-2018-april-18-2018.md

Roll-2-Roll Technologies LLC will be back again at Converters Expo with their new products in Web Position Sensors and Web Guiding Systems. Displays of the products demonstrating the easy to install and operate features based on a technology that allows the converter to handle any type of material or condition without the need to calibrate sensors. Real plug-and-play systems, simple design, easy operation, powerful results.



Your one-stop shop for all things converting is back in 2018 with additional exhibit space! Celebrating 11 years as the only one-day expo exclusively serving the converting industry, Converters Expo is returning to the Lambeau Field Atrium on April 17-18.



Converters Expo unites converters of paper, film, plastics and nonwovens with industry buyers, specialists and suppliers.



With over 700 attendees expected, Converters Expo continues to grow. Located in the heart of the nation’s top Converting Corridor, it is the place to find manufacturing partners, check out testing and prototyping equipment, meet with producers of disposables and learn the latest in flexo printing and packaging.

---

# Converters Expo 2020 - Virtual Exposition Kick Off

URL: https://r2r.tech/events/converters-expo-2020-virtual-exposition-kick.md

Roll-2-Roll Technologies will be present again at Converters Expo. However, this year your one-stop shop for all things converting, Converters Expo will be online and open for business 24-hours a day, 7 days a week. Join us when the virtual event kicks off on August 24-25 and will remain open and accessible through March 2021.



We will be introducing a revolutionary new sensor product and will be available for virtual demos of all our product line. Schedule demo using the time slots below.





For the past 13 years, Converters Expo has been the best source for converting solutions, from packaging and bags to tissues and diapers and more! No matter what you produce, you are sure to find a solution to your daily challenges. Converters Expo provides an ideal opportunity to virtually network with hundreds of prospective business partners and catch up with old friends.



[Register Today for Free](https://www.packagingstrategies.com/converters-expo/registration-pricing)

---

# Converters Expo 2024

URL: https://r2r.tech/events/converters-expo-2024.md

Come see Roll-2-Roll Technologies at the Converters Expo show this April. 

Converters Expo is just around the corner, and we're excited to showcase the SCU6x controller's game-changing features:

- 3x faster processing speeds
- 16x higher image capture resolution

Want to see it in action? Visit us at Booth 125 and use the following code for an exclusive discount!

> CE24ROLLVIP

Here are the instructions:

- Click Here to register online
- Select Attendee - Full Conference Registration type
- Enter the registrants email address and enter code: CE24ROLLVIP
- Enter Registrants information.
- Agree to the “Terms and Conditions” and click Submit Registration.

---

# Converters Expo 2025

URL: https://r2r.tech/events/converters-expo-2025.md

We're excited to announce that we will be exhibiting at the upcoming **Converters Expo on May 21st, 2025, at Lambeau Field in Green Bay, Wisconsin**! 🔍 Find us at: [Booth #125](https://www.packagingstrategies.com/converters-expo/floor-plan)

Mark your calendar for this opportunity to see our latest innovations in web guiding, measurement, and monitoring technology. We'll be showcasing **live demonstrations of our cutting-edge solutions throughout the day**. Stay tuned for more information about exclusive show specials and enjoy a special discount code for event entry: **CE25R2RVIP**. [Register Now!](https://na.eventscloud.com/ereg/newreg.php?eventid=798418&_gl=1*17axeu2*_ga*MTg4MzI0NjAyNy4xNzI4OTMzNzky*_ga_HMXLZKC13S*MTc0NDE0NDk4Ni4xNC4xLjE3NDQxNDUzMjcuNTguMC4w)

**Demo Schedule**

10:00 AM - SCU6x Controller: Web Guiding Applications 

10:30 AM - ODC Sensors: Width Measurement Solutions 

11:00 AM - 1DC Sensor: Official Product Launch & Demonstration 

11:30 PM - ODC Sensors: Multiple Slit Monitoring Applications 

  1:30 PM - Open Q&A with Our Technical Team

We look forward to seeing you there!

---

# Converters Expo 2026

URL: https://r2r.tech/events/converters-expo-2026.md

Join us at** Converters ****Expo**** 2026** to discover how our 1DC Sensor is solving solving problems related to splice detection, flag detection, defect detection, etc., across the converting industry.

---

# Converters Expo South

URL: https://r2r.tech/events/converters-expo-south.md

 Converters Expo South is a one day expo that unites converters of paper, film, plastics and nonwovens with industry buyers, specialists and suppliers.



With hundreds of attendees expected, Converters Expo South will be the place to find manufacturing partners, check out testing and prototyping equipment, meet with producers of disposables and learn the latest in flexo printing and packaging.



Attendees Can Expect to:
 • See the latest converting technology
 • Meet multiple vendors in informal setting
 • Network with industry peers
 • Find solutions to your daily challenges



Join us on February 5, 2019 at the Charlotte Convention Center in Charlotte North Carolina for Converters Expo South!

---

# Converters Expo South 2018 - February 6, 2018

URL: https://r2r.tech/events/converters-expo-south-2018-february-6-2018.md

Roll-2-Roll Technologies LLC will be present at the first edition of Converters Expo South with their new products in Web Position Sensors and Web Guiding Systems. Displays of the products demonstrating the easy to install and operate features based on a technology that allows the converter to handle any type of material or condition without the need to calibrate sensors. Real plug-and-play systems, simple design, easy operation, powerful results.



For over a decade Converters Expo has been bringing hundreds of suppliers and converter professionals together in the Green Bay, WI area for one day of demonstrations and networking on an expansive show floor.



Due to the overwhelming success of Converters Expo in Green Bay, we are introducing Converters Expo South in a new and convenient location to provide converters and industry professionals, in Southeastern region of the U.S., the opportunity to network and find solutions to their business needs.



Join us on February 6, 2018 at the Charlotte Convention Center in Charlotte North Carolina for Converters Expo South!

---

# Converters Expo South 2020

URL: https://r2r.tech/events/converters-expo-south-2020.md

Converters Expo South is a one day expo that unites converters of paper, film, plastics and nonwovens with industry buyers, specialists and suppliers.



With hundreds of attendees expected, Converters Expo South will be the place to find manufacturing partners, check out testing and prototyping equipment, meet with producers of disposables and learn the latest in flexo printing and packaging.

---

# Converters Expo South 2025

URL: https://r2r.tech/events/converters-expo-south-2025.md

Come see Roll-2-Roll Technologies at the Converters Expo South this February 19th, 2025. 

Converters Expo is just around the corner, and we're excited to showcase our line of ODC sensors and the SCU6x controller's game-changing features:

- 3x faster processing speeds
- 16x higher image capture resolution

Want to see it in action? Visit us at Stand 403 and use the following code for an exclusive discount!

> CES25ROLLVIP

Here are the instructions:

- Click Here to register online
- Select Attendee - Full Conference Registration type
- Enter the registrants email address and enter code: CES25ROLLVIP
- Enter Registrants information.
- Agree to the “Terms and Conditions” and click Submit Registration.

---

# Converters Expo South 2026

URL: https://r2r.tech/events/converters-expo-south-2026.md

Join us at** Converters ****Expo**** ****South**** 2026** to discover how our 1DC Sensor is solving splice detection across the converting industry.

---

# Fundamentals of Web Guiding

URL: https://r2r.tech/events/fundamentals-web-guiding.md

The event has already completed but a recorded version of the Webinar is now available on this web page: [https://r2r.tech/videos/web-guiding-fundamentals](https://r2r.tech/videos/web-guiding-fundamentals)

---

# ICE Europe 2019

URL: https://r2r.tech/events/ice-europe-2019.md

[ICE Europe 2019, Munich, Germany - Mar 12-14, 2019](http://www.ice-x.com/europe/2019/english/)

---

# ICE Europe 2019

URL: https://r2r.tech/events/ice-europe-2019-0.md

The World's Leading Exhibition for the Paper, Film and Foil Converting Industry is a biennial event that takes place at the Munich Trade Fair Centre in Germany.



ICE covers the key areas of the converting industry, presenting products and services from the following industry sectors:

 Materials
 Coating and Laminating
 Drying / Curing
 (Pre)Treatment
 Accessories
 Slitting / Rewinding
 Flexographic / Rotogravure Printing
 Finishing
 Factory Management / Waste Disposal
 Retrofits / Machine Upgrades
 Toll Coating / Converting / Slitting
 Control, Test & Measurement
 Software
 Services, Information & Communication



*categories*

---

# ICE Europe 2019

URL: https://r2r.tech/events/ice-europe-2019-1.md

As the World’s Leading Exhibition for the conversion of flexible, web-based materials, such as paper, film, foil and nonwovens, ICE Europe is the central marketplace for the international converting industry. At the biennial exhibition, manufacturers and suppliers of machines, systems, materials and accessories meet with industry specialists looking to invest in new production and converting solutions or to find out about the latest industry trends.



Roll-2-Roll Technologies LLC will be there showcasing their new technology and products in partnership with their sales representative for UK, TTS Systems.

---

# ICE USA 2019

URL: https://r2r.tech/events/ice-usa-2019.md

ICE USA is the leading event in the Americas for the converting of paper, film, foil, nonwovens and other flexible web-based materials.

---

# ICE USA 2019

URL: https://r2r.tech/events/ice-usa-2019-0.md

Visitors attend ICE USA specifically for the opportunity to get hands-on with the latest converting equipment, 
 technology and services. This group of buyers and decision makers who convert and process flexible web based
 materials come from around the globe to develop new business partnerships and are looking to network and
 learn from leaders in the converting industry.

---

# LabelExpo Americas 2018 - Sept. 25-27 2018

URL: https://r2r.tech/events/labelexpo-americas-2018-sept-25-27-2018.md

The largest event for the label and package printing industry in the Americas. Visit us in Booth 460, Hall A.

---

# LabelExpo Americas 2021

URL: https://r2r.tech/events/labelexpo-americas-2021.md

Labelexpo Americas, launched in 1989, is the largest label event in the Americas. Much of the recent growth is driven by ever-increasing numbers of Latin American printers.

---

# LabelExpo Europe 2019

URL: https://r2r.tech/events/labelexpo-europe-2019.md

Labelexpo Europe is the world's largest event for the label and package printing industry. The event launched in London in 1980 and it moved to Brussels in 1985, where it has remained since.



View hundreds of live demonstrations of the latest innovations, examine the most advanced collection of label and package printing technologies and acquire what your business needs to succeed.



Explore the world’s largest label and package printing trade show and advance ten steps ahead of the competition.

---

# Pack Expo 2025

URL: https://r2r.tech/events/pack-expo-2025.md

We're supporting one of sales partners, Web Tech LLC, by joining them at Pack Expo in Las Vegas from Sept. 29th through October 1st, 2025. Their booth is in the Upper South Hall, SU-27083. There you will be able to see our products in action, along with the new 1DC sensor. 

---

# R2R Conference Exhibit and Presentation - Advanced Web Guiding Applications and Concepts

URL: https://r2r.tech/events/r2r-conference-exhibit-and-presentation-advanced-web-guiding-applications-and-concepts.md

Roll-2-Roll Technologies LLC will be present at AIMCAL R2R Virtual Conference starting October 19th, 2020. A great opportunity to consult with us regarding solutions for web guiding and sensor applications. During the conference we will host live online demos. You can sign up for specific time slots to talk to one of our experts.



We will also participate with a presentation on "Advanced Web Guiding Applications and Concepts" by Dr. Aravind Seshadri, President of Roll-2-Roll Technologies LLC. The presentation will bon October 21st, at 12:45 pm CDT  Among the topics discussed will be irregular web edge conditions, center guiding applications, and other issues involved with advanced web guiding techniques.



Registration for the conference at the [AIMCAL R2R Conference Website](https://www.aimcal.org/2020-r2r-usa-conference.html)



Sign up for live demos at: [Live Demos](https://r2r.tech/schedule-live-demo)

---

# Roll-2-Roll Technologies LLC at Converters Expo 2022

URL: https://r2r.tech/events/roll-2-roll-technologies-llc-converters-expo-2022-0.md

Celebrate the 15th Anniversary of Converters Expo in the heart of the nation’s largest converting corridor. For a decade and a half, Converters Expo has been bringing converters of paper, film, plastics and nonwovens together with industry buyers, specialists and suppliers.



Join hundreds of converters looking to find manufacturing partners, discover the latest testing and prototyping equipment, network with producers of disposables, and learn the latest in printing and packaging. It’s a converting party you don’t want to miss!



Come visit us at Booth 41 in Converters Expo and tell us about your problem or issue with web guiding or monitoring.



Use [Code CE22R2RVIP in your registration](https://na.eventscloud.com/ereg/newreg.php?eventid=644837&_ga=2.124842701.617889026.1645462857-799079425.1645462857) and get a discounted registration fee.

---

# Roll-2-Roll Technologies LLC at Converters Expo 2022

URL: https://r2r.tech/events/roll-2-roll-technologies-llc-converters-expo-2022.md

We make your converting process easier to manage. Our business is to provide simple to operate solutions for difficult web guiding and monitoring applications. Web guiding applications in edge, center, line and contrast guiding. Web detection with our line of wide range ODC Linear Cameras for edge and contrast detection with a wide variety of applications. 

---

# Roll-2-Roll Technologies LLC will be at Converters Expo South 2022

URL: https://r2r.tech/events/roll-2-roll-technologies-llc-will-be-converters-expo-south-2022.md

**Converters Expo South** unites manufacturers of paper film, plastics, foil and nonwovens. Now in its 4th year serving the Southeastern converting industry, the Expo is expected to bring almost 100 exhibitors and more than 500 attendees to support the converting industry. Attendees can expect to see the latest converting technology, meet with vendors, network with industry peers and find solutions to daily challenges.



Visit us at Booth 42 where you will see how we make your converting process easier to manage. Our business is to provide simple to operate solutions for difficult web guiding and monitoring applications. Web guiding applications in edge, center, line and contrast guiding. Web detection with our line of wide range ODC Linear Cameras for edge and contrast detection with a wide variety of applications. 



![Roll-2-Roll Technologies LLC Booth 42 CSE 2022](https://r2r.tech/sites/default/files/inline-images/CSE2022BoothLocation.jpg)

---

# Webinar: Roll-2-Roll® Sensors: How it works and what are the applications?

URL: https://r2r.tech/events/webinar-roll-2-rollr-sensors-how-it-works-and-what-are-applications.md

The webinar will cover sensing and measurement technology that are used in Roll-2-Roll® Sensors. The presentation will cover:



- the fundamental working principle of the patented fiber optic technology
- how it differs from the conventional sensors
- benefits of the fiber optic technology
- fiber optic sensor technology for sensing and measurement applications such as  edge detection
- width measurement
- thread/string counting
- registration mark detection
- flag detection
- void/hole detection
- tear detection, etc.

---

# Webinar: Web Guiding Applications and Advanced Web Guiding Concepts 

URL: https://r2r.tech/events/webinar-web-guiding-applications-and-advanced-web-guiding-concepts.md

Join us to learn more about web guiding applications such as:



- Edge Guiding  Straight edge
- Fuzzy edge
- Jagged edge
- Wrinkles

  Center Guiding

- One sensor measuring two edges
- Two sensors, one each for an edge
- Moving sensor center guiding (mechanical sensor repositioning)
- Electronic guide point adjustment

  Line guiding

- Contrast/pattern guiding

  Line/contrast/pattern guiding on unwinds and rewinds Chasing application

- Mechanical 
- Electronic

  Master/slave application

- Mechanical master/slave
- Electronic master/slave application

  Oscillation

- Mechanical
- Electronic



We will also cover advanced web guiding topics such as:



- Turn bar
- Dead bar
- Controller concepts  Dead band
- Control systems type
- Actuator interlock
- Lock on lost edge



The session would be followed by Q&A. 



[Signup here](https://meeting.zoho.com/meeting/register?sessionId=1012977699)