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    • Roll Diameter and Tension Control

    Roll of packaging

    Ensure Quality and Reduce Unplanned Downtime

    Maintaining the correct level of tension on web materials is critical to ensure quality and minimize material breakage, wandering, and other process issues that can lead to unplanned downtime.

    Measuring roll diameter is fundamental to maintaining the correct amount of web tension. Variations in materials, material color, translucence and reflectivity, and environmental conditions can challenge a sensor’s ability to detect and measure these targets.

    Banner provides a range of sensing technologies capable of accurately and consistently measuring roll diameter to ensure the correct level of web tension.

    Challenges
    Solutions
    Featured Products
    Challenges of Roll Diameter Monitoring
    Laser sensor measures roll of metal
    The Importance of a Linear Output

    Choosing a Sensor for Roll Measurement

    Accurate roll diameter measurement and monitoring controls tension by enabling dynamic adjustment of wind and unwind speeds proportional to the change in the size of the roll. This protects materials from damage due to too much or too little tension. However, monitoring roll diameter accurately can be challenging, since this application requires an extremely linear output across the entire range of the sensor.  

    Linearity refers to how closely a sensor’s analog output approximates a straight line across the measuring range.  The more linear the sensor’s measurements, the more consistent the measurements across the full range of the sensor.  That is, the more linear the sensor, the more the output shows the correct change along a line of measurement.

    In the image to the left, the two-point teach option on the LE laser sensor is used to teach a full (4 mA) and an empty (20 mA) roll. The analog output provides a real-time gauge of the roll diameter. The more linear the sensor is, the more reliable the measurements between a full and and an empty roll.  With perfect linearity, half of the roll would be gone when the sensor gives 12 mA.  Sub-millimeter linearity is critical for reliable roll diameter monitor for tension control applications. 

    Solutions for Roll Diameter Monitoring
    Q4X sensor measures roll of multicolored labels
    Multicolor Materials with Many Color Transitions

    Roll Diameter Monitoring for Multicolored Labels

    • In consumer packaged goods industries, labels need to be applied to the products quickly and without error to keep production levels high.  
    • Accurately monitoring the diameter of a roll of labels and controlling the unwinding speed helps ensure that the process runs smoothly.  
    • A solution is needed that can accurately report the material level on a roll in order to prevent it from running out and delaying production.
    LE sensor measures roll of plastic shrink wrap
    Clear and Reflective Material

    Shrink Wrap Roll Diameter Measurement

    • Accurately determining the diameter of a roll of shrink wrap is essential to prevent material from running out during the shrink wrapping process and ensuring proper tensioning. 
    • As pallets enter the shrink wrapping station, a reliable solution must provide accurate data to alert operators if the roll of plastic wrap is running low.
    • The LE Series provides accuracy and repeatability when measuring challenging targets, like clear and reflective plastic, for reliable measurement of the shrink wrap rolls.
    • The analog output can be used to control wind or unwind speeds on the shrink wrap roll. The discrete output can be used to alert operators that the roll is almost empty.
    LE sensor measures roll of plastic shrink wrap
    L-GAGE LE550 - Roll Diameter and Unwind Speed
    Different Color Rolls, Including Very Dark Material

    Measuring Paper Rolls in a Range of Colors

    • Prior to being packaged, paper table coverings of varying colors, including very dark colors, are unwound from large rolls and cut to size. 
    • Insufficient or excessive tension can damage the table coverings, making them unsellable. To maintain the proper level of tension, the unwind speed must increase proportionately to the shrinking size of the roll.
    • The LE Series laser sensor reliably measures each roll, regardless of paper color, even extremely dark colors.  The superior linearity, repeatability, and resolution of the LE550 ensure reliable and consistent roll measurement and output.
    • Out of the box, the LE550 automatically scales across its entire operational range, from 100 mm to 1000 mm.  The LCD display provides real-time measurement and output information and makes it easy to assign set points and output levels.
    Featured Products
    LE laser measurement sensor
    LE Series

    1 m Laser Displacement Sensor

    The LE series linear array technology provides great performance and resolution regardless of detection objects color or sheen.

    • Ready to measure right out of the box
    • Easy adjustment with a two-line, eight-character intuitive display
    • Linear array provides repeatability and accuracy for challenging targets
    • Visible laser for small spot size and easy alignment
    • Models with IO-Link available
    Q4X laser measurement sensor
    Q4X Series

    Rugged Laser Distance Sensor

    全方位、堅固的雷射距離感測器提供卓越的性能，並能夠檢測小於1毫米的距離變化。

    • 提供數位訊號、類比（0至10 V或4至20 mA）、透明物件和IO-Link型號
    • 可靠的感應工作距離：從25 mm到610 mm
    • 可以偵測各種目標顏色、材料和表面的距離變化
    • 雙重教導模式（反射光強度+距離變化）是防錯應用的理想選擇，不需要反射鏡就可偵測透明物件
    • 符合FDA食品級認證的不鏽鋼堅固外殼, 環境防護等級達到IP69K
    Q4X laser measurement sensor
    More Roll Diameter Monitoring Applications
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