Domestic Web Guide Sensor Selection Guide (Part 1): Detailed Analysis of Three Series — Infrared, Ultrasonic and Optical Fiber
Table of Contents
Web Guide Sensors: The “Visual Perception Core” of Web Guiding Systems
In continuous web production lines for printing, lithium batteries, photovoltaics, nonwoven fabrics, pharmaceutical packaging and other industries, high-speed moving materials are prone to lateral deviation. This issue leads to cutting scrap, uneven coating, film breakage and unplanned line shutdowns.
As the detection module of the full automatic web guiding system, web guide sensors adopt optical and acoustic sensing principles to capture the offset of web edges, material centers and marking lines in real time. They convert collected data into standard electrical signals and transmit them to the web guide controller, which then drives servo actuators to implement real-time correction. Therefore, sensors serve as the fundamental core of the entire closed-loop web guiding system.
ARISE has focused on web control technology for 25 years and independently developed a full lineup of web guide sensors, covering four categories: infrared, ultrasonic, high-temperature fiber optic and CCD vision imaging sensors. Our products are compatible with all domestic web materials and complex workshop operating conditions. This chapter provides a detailed breakdown of the three mainstream sensor types: infrared, ultrasonic and fiber optic sensors, which are applicable to 90% of conventional web production scenarios.
US-A100 Infrared Web Guide Sensor
Basic Working Principle:
This infrared edge web guide sensor adopts modulated infrared light emission and reception. It identifies material edges based on the difference between light transmission and light blocking of the web material. Equipped with a built-in high-speed DSP for fully digital signal processing, it will not be affected by ordinary natural light and workshop lighting.
Core Advantages:
- Resolution up to 0.01 mm with high repetitive positioning accuracy;
- Seamless titanium alloy housing with IP54 dustproof and anti-corrosion performance, suitable for dusty printing workshops;
- Powerful anti-interference capability: resistant to 30,000 V static electricity and strong electromagnetic interference from inverters;
- Easy installation, powered by 12 V DC with standard 0–5 V analog output, fully compatible with all Enris web guide controllers including N300, S600 and S800 series
Applicable Web Materials & Scenarios:
Semi-transparent films, nonwoven fabrics, gauze, window screens and perforated webs; special coated materials sensitive to visible light, free from interference by intense ambient light.
Representative Model: US-A100 Infrared Sensor
US-A200 Ultrasonic Web Guide Sensor
Basic Working Principle:
The A200 ultrasonic edge web guide sensor emits high-frequency ultrasonic waves above 200kHz and calculates the edge position based on the time difference of echoes reflected by materials. It does not rely on light transmittance and delivers stable detection for both transparent and opaque materials.
Core Advantages:
- Compatible with all substrates, whether transparent or opaque, widely applicable to films, paper and aluminum foils.
- Free of optical attenuation, featuring an extended service life for long-term operation on high-temperature oven production lines.
- Fully digital zero-drift design ensures no signal lag under high line speeds.
- Supports installation at multiple stations including unwinding, winding and oven outlet positions.
Applicable Web Materials & Scenarios:
Suitable for transparent PET/POF films, multi-layer composite films, paper and thick textile fabrics; ideal for production lines with frequent switching between transparent and opaque webs.
Representative Model: US-A200 Ultrasonic Sensor
Note: Not applicable to materials with dense meshes, as meshes will cause distortion of acoustic reflection signals.
A300 / A300F High-Temperature Fiber Optic Web Guide Sensor
Basic Working Principle:
Infrared light is transmitted via optical fiber. The sensing probe contains no electronic components and adopts a high-temperature isolation structure. Optical signals can be transmitted over long distances, making the sensor suitable for high-temperature, narrow and enclosed working stations.
Core Advantages:
- Maximum temperature resistance up to 350°C, perfectly matching high-temperature stations such as coating ovens and thermal lamination processes.
- Compact probe size, easily installed on narrow-width equipment and confined mounting spaces.
- Resistant to strong light, static electricity and high-temperature oil contamination, specially designed for lithium battery separators and high-temperature films.
- Split fiber optic structure: only the probe is exposed to high heat while the main control circuit stays away from heat sources, greatly reducing failure rates.
Applicable Web Materials & Scenarios:
High-temperature coated films, lithium battery separators, thermal lamination substrates, webs processed through high-temperature drying sections, and thin metal foils.
Representative Models: A300 Standard Fiber Optic Sensor; A300F Dustproof Reinforced Version
Quick Selection Comparison Table of the Three Types of Sensors
| Sensor Type | Core Advantages | Limitations | Priority Industries |
| US-A100 Infrared | High precision, compatible with perforated materials, cost-effective | Unable to detect fully ultra-transparent films | Printing, nonwoven fabrics, cigarette packaging, textiles |
| US-A200 Ultrasonic | Works for both transparent and opaque materials, withstands regular high-temperature conditions | Fails to detect perforated materials | Film slitting, food packaging, lamination production lines |
| A300 Fiber Optic | Resists temperatures up to 350°C, fits compact stations, dedicated for lithium battery industry | Higher cost than infrared and ultrasonic sensors | Lithium batteries, photovoltaic coating, thermal lamination processes |
Core Competitive Advantages of Enris Matching Sensors
1. Full-chain self-developed integrated supporting solutions
One-stop in-house production covering infrared, ultrasonic, fiber optic and CCD vision sensors, S-series controllers, SE servo actuators and customized web guide roller frames. All devices share fully compatible signal protocols for more stable overall linkage commissioning, eliminating the need for cross-brand compatibility modifications.
2. In-depth optimization tailored for domestic workshop conditions
Specialized hardware and software upgrades are developed to address complex production environments common in Chinese factories, including static electricity, dust, high heat and electromagnetic interference from inverters. The design effectively resolves prevalent industry issues such as signal drift, false detection and missed detection during long-term continuous operation.
3. Cost-effectiveness & fast delivery
No long lead times typical of conventional equipment suppliers, with sufficient stock maintained domestically. Local offices are established in Guangdong, Jiangsu, Zhejiang and Shandong provinces, offering on-site survey and commissioning by professional engineers. Overseas branches in Vietnam and Indonesia provide localized technical services for export-oriented manufacturers.
4. Comprehensive intellectual property backing
The company holds multiple invention patents related to sensing technology and software copyrights for self-developed sensing algorithms. Fully independent control over core algorithms enables customized signal optimization programs tailored to customers’ unique web materials and special process requirements.
5. Next Issue Preview
The next chapter of *Domestic Web Guide Sensor Selection Guide (Part 2): Detailed Introduction to CCD Vision Web Guide Sensors* will elaborate on A400/A600 vision web guide sensors, with an in-depth analysis targeting high-precision applications including color printing, pattern line tracking and label positioning.
About Chongqing ARISE
Chongqing ARISE Technology Co., Ltd. With 25 years of exclusive focus on web control technology, ARISE is recognized as a Chongqing Specialized, Refined, Unique & Innovative “Little Giant” Enterprise. The company has obtained ISO9001 Quality Management System Certification and Integration of Informatization & Industrialization System Certification, while its products hold EU international certifications including CE, EMC and ESD.
Main Products: Full range of intelligent web processing equipment, including vision inspection systems, coating quality tracking systems, web guiding systems, tension control systems, static frame monitoring systems, width measurement and thickness measurement equipment.
Our service network covers more than 150 countries and regions worldwide.