Specifications, performance, compatibility
Quick Answer:
Short Answer
Infrared for high-contrast, white light for low-contrast patterns, UV for fluorescent inks.
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.
Quick Answer:
Short Answer
No. Wide sensing ranges (48-960 mm) let the sensor see the entire area without mechanical movement.
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.
Quick Answer:
Short Answer
Minimum line width is 2 mm. Negative space guiding (tracking gaps between features) is also supported.
Roll-2-Roll® Sensors can detect and track lines with a minimum width of 2 mm (0.08 in). The sensors also support negative space guiding—tracking the gap between printed features (such as the white space between labels) rather than a printed line. This eliminates the need to print a dedicated registration line, saving ink costs and allowing closer trim to printed edges.
Quick Answer:
Short Answer
No. The same ODC or 1DC sensor handles edge, line, center, and contrast guiding.
No. With Roll-2-Roll® Sensors, you do not need to purchase or install a separate sensor for line/contrast guiding. The same ODC or 1DC sensor family handles edge detection, line guiding, center guiding, and contrast guiding. For most high-contrast applications, the standard infrared light source works for both edge and line detection. For low-contrast or UV-printed lines, white light or UV light source options are available.
Quick Answer:
Short Answer
Loss of Contrast Logic holds the guide position during gaps, then resumes tracking when the feature returns.
The Roll-2-Roll® Controller includes Loss of Contrast Logic specifically for this situation. When the sensor encounters a gap where the tracked feature disappears (such as the space between labels), the web guide holds its current position. When the sensor sees the same feature again—matching the width and hue characteristics taught during setup—tracking resumes automatically. This prevents the "hunting" or crashing behavior common with traditional line sensors.
Quick Answer:
Short Answer
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.
Quick Answer:
Short Answer
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.
Quick Answer:
Short Answer
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.
Quick Answer:
Short Answer
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.
Quick Answer:
Short Answer
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.