Flag Detection

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.

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.

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.

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.

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.