Specifications, performance, compatibility
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Yes. A single Roll-2-Roll sensor handles both edge detection and line/contrast guiding without swapping sensors.
Yes. Unlike competitor systems that require separate sensors for edge detection and line/contrast guiding, a single Roll-2-Roll® Sensor 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.
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Moving sensors need two fighting loops (guide web + chase edges). Roll-2-Roll® Sensors use one simple loop.
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 that see both edges without moving—only one control loop is needed to maintain centerline, simplifying commissioning and improving stability.
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1,920mm (75.6 in) using dual [odc 960] sensors - widest in industry with 0.127mm resolution.
Roll-2-Roll offers the widest center guiding capability in the industry. Using two 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.
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Calculate: (max width - min width) ÷ 2 + wander margin. Select next larger sensor size.
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 (96mm window) as the ODC 48 would be too small.
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Wide sensing range (48-960mm) eliminates mechanical sensor positioners, reducing failures and maintenance.
Roll-2-Roll® 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 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.
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No. Single wide sensors (up to 960mm) can see both edges. Wide webs may need two sensors.
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, ODC 768, or 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.
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Center guiding averages edge defects, ignores wrinkles, and ensures symmetric margins for coating/laminating.
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.
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ODC uses external controller with touchscreen. 1DC has built-in controller for PLC integration. Same accuracy.
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.
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Roll-2-Roll® Sensors achieve 0.0635mm resolution with >99.9% repeatability on all materials.
Roll-2-Roll® 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.
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Roll-2-Roll sensors range from 48-960mm. Choose based on web wander plus safety margin.
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.