Quick Answer:
Short Answer
Yes. The sensor spatial awareness across its full pixel array enables real-time detection of splices, flags, tears, voids, and other surface anomalies without additional hardware.
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.