Technical

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.

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 can apply dynamic compensation—electronically delaying the feed-forward signal to match the transport time difference.

Both SCU5 and 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.

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, ODC 768, or 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.

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.

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.

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.

Yes. The SCU5 and 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.

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 controller includes an integrated motor driver, eliminating the need for separate drive cabinets and simplifying installation.

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.