Web and Edge Guiding

EZ-Array detects the edges of a web of brown material

Ensure Continuous Flow of Materials

Reliable web and edge guiding ensures a continuous flow of product through machine processes, minimizes downtime, and prevents material damage and loss.

Sensors are frequently used to monitor and control webs by measuring the web as it travels on the line. 

Banner’s expertise in sensing technology allows us to offer solutions that consistently and accurately measure web material, keeping it centered on the line for continuous flow through the system.

Challenges for Web and Edge Monitoring

A fiber optic array detects the edge of a film in battery assembly
Precise Control and Challenging Targets

Like many industrial sensing applications, web and edge guiding applications often involve targets that are traditionally challenging for sensors to detect, including clear, reflective, and extremely dark targets. 

In addition to material texture, reflectivity, and translucence, the high-speed operation of web guiding equipment can challenge a sensor’s ability to detect and measure the material reliably.

Problem-solving sensors from Banner Engineering provide reliable edge detection for web guiding applications.  See a few exmaple applications below, or contact us to discuss your specific application. 

Example Web and Edge Guiding Applications

EZ-ARRAY light grid detects the edge of a clear web
Web Guiding for Clear Material

Detect Plastic, Glass, and Other Clear Webbing

  • Clear objects are some of the most challenging to detect and measure reliably.  
  • Web material may also be translucent, and a reliable solution is needed to accurately perform sensing tasks such as edge guiding, loop tension control, hole sizing, and profiling. 
  • Banner Engineering has created a special class of EZ-ARRAY specifically designed to detect clear objects.
  • By customizing standard EZ-ARRAY receivers to successfully detect low contrast and operate at a lower sensing range (30 to 1500 mm), Banner has enabled EZ-ARRAY clear object measuring light grids to detect translucent objects such as glass and clear webbing.
EZ-ARRAY light grid detects transitions on a web of carpet
Detect the Edge of Webs with Multiple Transitions

Edge Guiding on a Carpet Web

  • Determining the location of the two edge transitions on carpet web is important in carpet manufacturing: the edge from air to selvage and the edge from selvage to tufting.
  • Measuring and monitoring these transitions while the web is running is more cost-effective than risking expensive waste in post-manufacturing inspections.
  • As the carpet web passes through a pair of EZ-ARRAY measuring light curtains, the two sticks configured for Nap Detection mode monitor the process in action. 
  • The EZ-ARRAY detects the selvage edge and tufting edge and sends data to the web control system, which can then make necessary adjustments to keep the carpet in line.
EZ-ARRAY light grid detects transitions on a web of carpet
A fiber optic array detects the edge of a film in battery assembly
Precise Edge Guiding in Tight Spaces

Edge Guiding in Battery Manufacturing

  • Lithium battery assembly combines rolls of anode, cathode, and separator film into a larger roll of battery cell material.
  • Misalignment of the three materials can cause material waste, jam the machine, or worse, result in recalls or a faulty final product.  Even small variation to the left or right can be costly. 
  • Pairing Banner Engineering's DF-G3 Series fiber optic amplifier with a fiber array creates a high power fiber optic assembly that detects the slightest movement in either direction.  
  • Tight beam spacing and consistent light intensity across the entire array enable the fiber optic assembly to precisely detect very slight shifts in the rolls of film. 
  • When edges are not aligned properly, the machine automatically adjusts position to keep the film aligned. 

Featured Products

EZ-ARRAY Series light grid

Measuring Light Grid

  • IO-Link, Modbus-RTU, and RS-485 models are available
  • Applications include edge and center-guiding, loop tension control, hole sizing, parts counting and on-the-fly product sizing and profiling.
  • Closely spaced infrared beams detect objects as small as 5 mm wide edge resolution is 2.5 mm.
  • Controller functionality is built into the receiver, so basic setup requires no controller, software, or PC.
  • Easy-to-use software is included for advanced configuration, using a PC.
  • Configuration options include 14 measurement modes, three scanning methods, two analog and two discrete outputs and a serial output.
  • Range is 4 meters.
  • Array heights range from 150 to 2400 mm.
DF-G3 Fiber Optic Amplifier
DF-G3 Series

High Power Fiber Optic Sensor

DF-G3 Fiber Optic Amplifier