Edge 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.

Roll-2-Roll® sensors work on nearly all web materials, including many that defeat conventional sensors:

• Clear films — PET, BOPP, cellophane, and other transparent materials work without special settings
• Mesh and porous webs — accurately measured where conventional sensors fail
• Metals and foils — aluminum, copper, steel strip
• Textiles and nonwovens
• Glass and carbon fiber

The patented light-scattering and spatial-filtering technology detects edges and features regardless of material opacity or surface finish. No recalibration is needed when switching between materials.

One capability is unique to Roll-2-Roll® sensors: detecting clear film edges under vacuum. Ultrasonic sensors cannot function without air as a transmission medium, and camera-based systems struggle with transparent materials. Roll-2-Roll® sensors are the only sensing technology that reliably detects clear films in vacuum environments.

The one challenging material is matte carbon black — the solution is to angle the light source perpendicular to the web to increase light scattering at the edge.

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.

Both Roll-2-Roll® sensors and traditional line scan cameras capture one-dimensional scans to build profiles of continuously moving webs. However, Roll-2-Roll® sensors use patented linear fiber-optic arrays instead of circular lenses. This fundamental difference delivers several advantages:

• 100x more light sensitivity — larger pixels (63.5 µm vs. 5–14 µm in conventional cameras) capture significantly more light per pixel
• Working distance under 15 mm — the 1:1 magnification of fiber optics enables compact installations in tight spaces
• Zero lens distortion — linear fiber optics behave like telecentric lenses, eliminating the aberrations and geometric errors inherent in circular optics
• No vision engineer required — adaptive edge detection algorithms are built in, so setup takes minutes instead of the weeks typically required for traditional line scan camera integration

The result is line-scan-camera-grade measurement capability — pixel counts from 768 to over 14,000, scan rates above 200 kHz — without calibration, custom software, or specialized imaging expertise.

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

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.

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.

Roll-2-Roll® Sensors provide true spatial awareness—not just binary on/off detection:

This accuracy is maintained across all material types without recalibration—critical for precision applications like battery electrode coating, optical film production, and high-speed converting.

Roll-2-Roll® Sensors are vacuum compatible and can detect clear films in vacuum environments. This is a unique capability that no other edge detection technology can match:

• Ultrasonic sensors cannot function in vacuum—no air means no sound waves for detection
• Many optical sensors struggle with clear films even in normal atmosphere

Roll-2-Roll Technologies fiber-optic technology solves both problems, making it the only solution for applications like:

• Glass manufacturing processes
• Vacuum coating operations
• Semiconductor manufacturing
• Specialty film production