Roll Tagger builds a digital map of every roll as it winds — recording defects, splices, and quality events at precise positions. On the unwind, that map drives automated waste removal. No physical tags. No manual watching. The system runs entirely on-premise using industrial Revolution Pi controllers with dual encoder inputs for sub-millimetre position precision.
As material winds onto the roll, Roll Tagger records every millimetre. Dual encoder data calculates real-time diameter, thickness, speed, and rotation count — building a precise digital twin of the roll.
On the unwind, Roll Tagger loads the rewind map and plays it back against the live encoder feed. Events trigger configurable machine actions — stop, jog, or skip — eliminating manual watching.
Track defects through multiple processes and remove at the final operation such as slitting. Full roll lineage and parent-child traceability across every production station.
Automatic quality checks at every 10-wind milestone comparing actual to expected position from the source rewind map. Deviation alerts for positional anomalies.
Three-queue architecture (input, output, backlog) for multi-station workflows. Rolls transfer automatically between devices via .rtag file handoffs over the local network.
Digital I/O to interface with vision systems, splice detectors, and turret rewinders. REST API and batch CSV import for MES/ERP integration.
Digital twin of every roll, three-queue architecture, yield analytics, plant-floor deployment.
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RevPi Connect 4, RevPi DIO and absolute rotary encoder: industrial, off the shelf.
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What is involved from first install to first roll.
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User manual, support documentation and FAQ for customers. Login required.
Learn moreRoll Tagger is the plant I/O interface for the roll record. Beyond encoder position and roll identity, it captures the handful of events that let Roll Grader read every defect in the context of the line.
| Job start and end | Anchors the startup template and names the product whose rules apply |
|---|---|
| Line speed setpoint change | Shifts drying, tension and gauge, and every MD-to-time conversion |
| Roll change and splice | A new substrate roll means a new genealogy link and a tension transient |
| Consumable change | Screen pack, doctor blade, anilox, cylinder, slitter blade, adhesive batch: resets the ageing clock |
| Setpoint change | Melt, die, dryer, nip, tension, impression: an expected, lagged response |
| Stop and restart | Restart is a mini-startup; a stop marks dwell damage at the dryer or nip |
| Operator confirmation | One-tap feedback on the advisor's diagnosis, which tunes the cause tables |
Sources: PLC over OPC UA or digital I/O, MES over MQTT/UNS, and the operator terminal. Where the PLC feed is not yet logged, the operator terminal covers job start and consumable changes on day one.
| Encoder sampling | 100ms intervals |
|---|---|
| Position precision | Sub-millimetre |
| Controller | Revolution Pi Connect 4 |
| Encoder interface | RS485 Modbus RTU |
| I/O expansion | 14 DI / 14 DO (RevPi DIO) |
| Data storage | Local SQLite, offline-first |
| Integration | REST API, digital I/O, CSV |
| UI | Browser-based (React + WebSocket) |
| Licensing | Perpetual, per line and per device |