Complete Guide to Web Guiding Sensor Types (Part II) — CCD Vision Image Sensors

In our previous installment, we provided a detailed overview of three fundamental types of web guiding sensors: infrared, ultrasonic, and optical fiber sensors. These products are primarily used for web edge tracking and are well-suited for simple working conditions such as conventional films, non-woven fabrics, and high-temperature substrates.

This installment introduces ARISE’s self-developed A400/A600 Series CCD Vision Image Sensors. As high-precision specialty web guiding sensor devices, they enable multi-dimensional recognition of patterns, color marks, guide lines, and web edges, making them highly suitable for complex production scenarios including color printing, pharmaceuticals, lithium batteries, and high-end labels.

Basic Working Principle of CCD Vision Image Sensors

CCD vision web guiding sensors are equipped with high-definition CCD imaging lenses and high-speed processing units, effectively providing the web guiding system with a high-definition industrial vision acquisition module:

Featuring a self-adaptive adjustable supplementary light source, it captures complete images of the web surface in real time;

• Using self-developed image recognition algorithms, it simultaneously detects multiple features including web edges, printed lines, color blocks and color marks, and custom patterns;
• It compares the captured images against standard reference images in milliseconds, accurately calculates the lateral web deviation, and outputs standardized electrical signals to the N/S series web guiding controllers;
• It coordinates with servo drives to perform dynamic correction, integrating four core functions: edge tracking, line tracking, color mark tracking, and pattern centering;
• Unlike infrared, ultrasonic, and optical fiber sensors, which rely on single-point boundary detection, CCD vision sensors employ full-field image recognition logic, making them a core supporting sensor device for demanding production lines such as multi-color printing and precision coating.

Detailed Overview of ARISE’s Two Mainstream CCD Vision Sensors

A400 Economical CCD Vision Sensor

Hardware Configuration

Equipped with a standard CCD imaging lens and a 64-bit dual-core high-speed processor, the A400 CCD image sensor delivers fast sampling response. Featuring a 4.3-inch color touch display, it provides real-time visualization of captured images, lowering the threshold for operation and commissioning.

Core Performance Advantages

• Built-in adaptive ambient light compensation algorithm, effectively resisting interference from workshop lighting and natural light, ensuring stable operation with no signal drift;
• Supports three detection modes: web edge, monochrome lines, and single color marks, with one-touch switching to adapt to different materials;
• 12-24VDC wide-voltage power supply, seamlessly compatible with ARISE’s full range of web guiding controllers including N300, S600, and S800;
• Dust-proof and oil-resistant body design, suitable for conventional production conditions such as general printing, textiles, and rubber films.

Applicable Scenarios

Monochrome printed webs, non-woven fabrics, rubber films, general self-adhesive labels, and single-layer laminate films. Suitable for line tracking and edge tracking requirements on low to medium-speed production lines.

A600 High-Precision CCD Vision Sensor

Hardware Configuration

A600  CCD image sensor is equipped with a 5-megapixel high-definition area scan CCD camera, offering a standard field of view of 40mm × 40mm, positioning accuracy down to 0.02mm, and ultra-fast sampling at 1ms. It supports simultaneous recognition of complex multi-color patterns.

Core Performance Advantages

• Supports recognition of multi-color blocks, multi-color marks, complex printed patterns, and multi-layer register mark identification, making it suitable for high-end color printing applications;
• High-speed imaging with no motion blur, capable of matching high-speed web production lines up to 400m/min;
• Supports storage of multiple image template sets, allowing one-touch recall of preset parameters when changing production materials, reducing downtime for commissioning;

Applicable Scenarios

Cigarette package color printing, multi-layer composite flexible packaging, pharmaceutical blister films, color labels, lithium battery electrode coating positioning, and optical functional films.

Application Differentiation Comparison Table: CCD Vision Sensors vs. Infrared/Ultrasonic/Optical Fiber Sensors

Sensor Type	Core Detection Capability	Recognition Target	Positioning Accuracy	Applicable Conditions
Infrared Sensor	Web edge tracking	Translucent films, non-woven fabric edges	0.01mm	General printing, non-woven fabrics, room-temperature film production lines, film slitting, and lamination production
Ultrasonic Sensor	Web edge tracking	Edges of transparent and opaque substrate materials	0.1mm	Scenarios with frequent substrate changeovers
Optical Fiber Sensor	Web edge tracking	Edges of thin materials in high-temperature ovens	0.03mm	Coating, thermal lamination, high-temperature applications, and confined installation spaces
A400/A600 CCD Vision Sensor	Edge tracking + Line tracking + Color mark tracking + Pattern centering	Web edges, printed lines, multi-color marks, custom patterns	0.02mm	Color printing, pharmaceuticals, lithium batteries, and high-precision production of high-end labels

Selection Summary: For applications requiring only web edge tracking, infrared, ultrasonic, or optical fiber sensors are recommended. For production lines with requirements for printed lines, color registration, or pattern alignment, CCD vision image sensors are the preferred choice.

Core Advantages of the CCD Vision Sensing System

1. Full-Series Self-Developed Complete Solutions for Stronger System Synergy

The A400/A600 vision sensors, ARISE N/S series web guiding controllers, SE servo drives, and custom guiding roller frames all utilize a unified underlying communication protocol. The entire equipment set is independently developed and manufactured, ensuring smooth signal matching. Purchasing the complete set reduces the workload of equipment interfacing and commissioning.

2. Algorithms Specifically Optimized for Domestic Workshop Conditions

With algorithms optimized for common production environment challenges found in domestic factories—such as electromagnetic interference, dust and oil contamination, strong workshop lighting, and temperature fluctuations—the system ensures stable, long-term continuous operation through enhanced image filtering and signal compensation algorithms.

3. Comprehensive Localized Service System for Efficient Delivery and After-Sales Support

With offices established in multiple regions across China, staffed by professional on-site engineers, we provide services including production line site surveys, equipment installation, and commissioning. Standard models are available from stock, shortening the waiting period for customer production line upgrades. Additionally, with overseas service networks in Vietnam and Indonesia, we support the implementation of projects for export customers.

4. Proprietary Core Algorithms with Support for Customized Development

Leveraging the company’s 6 invention patents and multiple software copyrights for vision algorithms, we can provide specialized optimization of image recognition programs for customers’ special substrates and custom printed patterns.

Mainstream Industry Applications

1. Cigarette Package Color Printing Industry

Line tracking and web guiding for multi-color registration and complex patterns on metallic cardstock, precisely capturing fine register marks to significantly reduce waste caused by registration misalignment.

2. Pharmaceutical Packaging Industry

Color mark positioning for aluminum-plastic blister films and pharmaceutical laminate films, ensuring precise dimensions in slitting and sealing processes, and meeting clean production standards.

3. Lithium Battery / Photovoltaic Industry

Electrode coating positioning and photovoltaic backsheet printed line centering, delivering micron-level control accuracy to prevent product defects caused by coating misalignment.

4. Flexible Food Packaging Industry

Color mark tracking for color composite packaging bags and self-adhesive label printing, compatible with high-speed bag-making machines for synchronized guiding, ensuring finished patterns are properly aligned and consistent.

About ARISE

Chongqing ARISE Technology Co., Ltd. has been focusing on web control for 25 years. The company is recognized as a “Specialized, Refined, Distinctive, and Innovative” (SRDI) “Little Giant” enterprise in Chongqing, certified with ISO 9001 and the Integration of Informatization and Industrialization management system, and its products have obtained EU CE, EMC, and ESD international certifications.

Main Products: Vision Inspection Systems, Coating Quality Tracking Systems, Web Guiding Systems, Tension Control Systems, Web Monitoring Systems, Width Measurement, and Thickness Measurement — a full range of intelligent web control equipment. Service network of Arise web control products spans over 150 countries and regions worldwide.