Skew detection and web edge control

When a material web drifts laterally out of position in a production line, the consequences are immediate: misregistration in multi-color printing, defective cuts and folds in packaging, uneven winding edges, and in the worst case machine stoppages or equipment damage. For reliable skew detection and web edge control, Tippkemper-Matrix provides optoelectronic sensors that continuously and non-contactually detect the lateral position of a running material web – delivering an analog output signal of 4–20 mA or 0–10 V proportional to the current web edge position, directly usable as a control variable in automated web guiding systems.

Operating Principle: Analog Output Signal Proportional to Web Edge Position

The defining feature of Tippkemper-Matrix sensors for web edge control is their continuously variable analog output signal: depending on the current position of the web edge within the sensor's detection range, the device outputs a proportional value between 4 and 20 mA or 0 and 10 V. This measured value represents the precise lateral position of the web and can be fed directly into a higher-level control loop without any additional signal conditioning – into a PLC, a dedicated web guiding controller, or a decentralized drive system.

This measurement principle enables not only the detection of an already-occurring skew, but also continuous, proportional control of the web position – meaning active, anticipatory correction before the web leaves its tolerance range.

The sensors operate fully non-contactually and wear-free: no mechanical contact with the running material web, no abrasion wear, no contamination of the sensor by the web material – a decisive advantage in high-speed production lines and when handling sensitive web materials.

Printing and Packaging Industry

In rotary printing machines and packaging lines, print webs and packaging materials are guided at high speed. Even minimal lateral offsets cause registration errors in multi-color printing or defective punching and folding operations. The Tippkemper-Matrix sensor detects every positional deviation of the print web in real time and delivers the analog correction signal for precise, continuous alignment – without interrupting the running print process.

Paper and Textile Industry

In the production of paper rolls and textile webs, web edge control is a prerequisite for consistent winding quality and minimal material loss. If the web drifts laterally from its target position, uneven winding edges, edge-trim waste, and quality defects in the final product result. The sensor provides the continuous analog signal for precise web position tracking throughout the entire production run.

Film Production

Plastic and metal films are particularly sensitive to mechanical contact. The non-contact operating principle of the Tippkemper-Matrix sensor protects the film surface from scratches or deformation, while simultaneously detecting the web edge precisely and enabling exact control of the slitting or winding unit relative to the current web position.

Metal Strip and Plastics Processing in Production Lines

In rolling and coating lines for metal strips, and in production lines for plastic panels or wood-based board, web width, material stiffness, and line speeds place particular demands on sensor robustness. Tippkemper-Matrix sensors are designed for industrial continuous duty and deliver their analog signal stably even under mechanical vibration, dust, and varying ambient conditions.

Food Packaging Industry

In the processing of food packaging films and webs, hygienic production conditions apply alongside precision requirements. The non-contact sensor technology from Tippkemper-Matrix does not intervene in the web path and leaves no contact points – a hygienic advantage in environments with elevated cleanliness requirements.