Frequently Asked Questions

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 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.

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 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.

Roll-2-Roll® Sensors are essentially one-dimensional line scan cameras—but without the complexity of traditional machine vision systems:

This is a major unlock: sophisticated 1D imaging capability that production staff can set up and maintain without specialized training or ongoing support costs.

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.

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 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.

No. Roll-2-Roll® 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 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 enable true "set and forget" operation.

Both product lines provide the same edge detection accuracy and material versatility. The difference is in how they integrate:

ODC 96 Family

• Best for: End users who want easy setup with touchscreen interface
• Requires SCU5 or SCU6x controller
• Intuitive touchscreen operation
• No coding required
• Sensing ranges: 48-960mm

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.

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.

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.

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.

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