EdgePilot™ EP-3AX Web Guiding System
Web guiding engineered for your machine.
EdgePilot™ EP-3AX automatically tracks both edges of a moving web, continuously calculates its position and width, and maintains the required centreline or offset using industrial Siemens automation hardware.
Sensors that move with your web.
Edge sensing, Siemens controls and servo steering, configured as one system for your line.
Motorised sensor carriages
Ultrasonic sensors that automatically follow the left and right edges.
Servo steering axis
Corrects the web's lateral position continuously, to centre or an operator-set offset.
Siemens SIMATIC MTP400 Unified Comfort Panel
4.3" touchscreen (7" optional) with live width, position, setpoint and diagnostics.
Siemens S7-1200 PLC
Siemens S7-1200 CPU 1214C PLC and three PROFINET servo drives. Mechanical and sensor assembly IP54.
Consistent web position. Less intervention.
When material drifts sideways, it shows up as uneven slits, poorly wound rolls, misaligned laminates and extra trim. EdgePilot holds the web where it should be, so the line runs consistently without constant manual correction.
Reduce waste
Less scrap, rework and trim from edge drift, lateral misalignment and uneven slitting.
Reduce operator intervention
Reduce manual web-position correction during production, so operators can focus on running the line.
Maintain consistent web position
Hold the web to a centreline or set offset, automatically, through width changes and roll changes.
Track both edges. Follow the width. Correct the path.
Reliable real-world guiding, typically within about ±0.5 mm under stable running conditions. Installed performance depends on web tension, stability, roller condition and mechanical alignment.
1. Sense both edges
Two ultrasonic sensors detect the left and right edges of the moving web, continuously.
2. Follow the web width
The sensors sit on motorised carriages that automatically follow each edge as the web width changes, so operators don't need to manually reposition the sensors.
3. Calculate width and position
A Siemens S7-1200 PLC continuously calculates live web width and the web's position against your setpoint: centred, or a set offset.
4. Steer it back
A servo-driven steering axis corrects the web's lateral position on your existing steering roller, continuously and automatically.
A web-guiding system engineered around your machine.
Not just a web guide off the shelf: a defined, repeatable product configured to suit each machine. Designed and built in New Zealand by Solve Electrical.
No reworking your line
Sized to your machine, not a catalogue range, so the guide fits your line instead of the line being changed to fit the guide.
Less time on product changes
When the web width changes, the sensors reposition themselves, so operators aren't stopping to move them by hand.
Siemens industrial controls
Widely supported Siemens industrial hardware with built-in diagnostics and service modes, backed by direct engineering support from Solve.
Engineered around your existing line, or built in from the start.
EdgePilot retrofits to existing steering rollers and steering arrangements, making it a practical upgrade for ageing machines running manual adjustment or obsolete, costly-to-maintain guides. Units are already running in NZ plants, including retrofits to ageing machines.
Retrofit to existing lines
EdgePilot is supplied as a complete web guiding system, built to suit your minimum and maximum web widths, with mounting configured for your machine. It can replace an existing web guide or upgrade a manually adjusted system, ready for installation and integration by your team or a local contractor. Installation and commissioning by Solve available in New Zealand.
New machine integration
For machine builders and plants specifying new lines, EdgePilot can be designed into the original machine.
Built for processes where material position is critical.
EdgePilot suits packaging, converting, extrusion, coating, laminating, slitting, rewinding and other continuous production processes requiring accurate lateral positioning of materials such as film, paper and foil.
Flexible packaging
Consistent lateral web alignment through printing and laminating.
Plastic film
Clear and printed films. Ultrasonic edge sensing works on transparent film.
Paper and converting
Straighter rolls, cleaner edges, less trim.
Coating and laminating
Hold the web centred through the coater.
Slitting and rewinding
Even slits and flat, square rolls.
Extrusion, foil and more
Extrusion lines, foil and other continuous material-handling processes.
EdgePilot EP-3AX at a glance.
Every unit is configured to the host machine. Full specifications, operator modes and integration details are in the datasheet (Rev 1.5).
| Guiding method | Dual-edge automatic web guiding |
|---|---|
| Typical accuracy | Approx. ±0.5 mm under stable running* |
| Edge sensing | 2 × ultrasonic sensors on motorised carriages |
| Sensor measuring span | 20 mm per sensor |
| Web width | Custom-configured to suit your application. Measured live. |
| Control | Siemens S7-1200 PLC; SIMATIC MTP400 Unified Comfort Panel 4.3" HMI, optional 7" display |
| Drives | 3 × PROFINET servo axes |
| Machine interfaces | Application-dependent, configured during integration |
| Line speed | Application-dependent |
| Supply | 230 VAC, 1-phase, 50/60 Hz (other configurations available) |
| Environment | Indoor industrial, 0–40 °C, <80% RH non-condensing. Mechanical and sensor assembly IP54. |
| Pricing | On application, configured to your machine and line |
| Lead time | Typically around 4 weeks from order to commissioning |
| Warranty | 12 months on supplied equipment |
* ±0.5 mm is a practical typical figure, not a guaranteed tolerance.
The datasheet is a free download, no form required. Mechanical drawings are provided once we've confirmed your requirements, as each unit is built to your machine.
Confirm requirements
You provide your minimum and maximum web widths and mounting frame length.
Build & test
We fabricate, automate, wire and test your complete EdgePilot system in our New Zealand workshop.
Supply & support
Shipped ready for installation and integration by your team or a local contractor, with documentation and direct technical support from Solve.
Common questions about EdgePilot.
Yes. EdgePilot retrofits to existing steering rollers and steering arrangements. Each system is built to suit your minimum and maximum web widths, with mounting configured for your machine.
Each system is configured to the host machine. Machine interfaces are application-dependent, so we work out what your line needs when we confirm requirements, then supply EdgePilot ready for installation and integration by your team or a local contractor.
EdgePilot is compatible with transparent film. Its ultrasonic sensors detect the edges of clear film, where optical sensors can struggle.
12 months' warranty on supplied equipment, documentation with every unit, and direct technical support from Solve.
Pricing is on application, because each system is configured to your machine. Typical lead time is around 4 weeks from order to commissioning.
Send us a short description of your machine and application. Photos, a video or drawings help if you have them.
See EdgePilot running.
Talk to us about your application or arrange a live video demonstration.
Manufacturers we work with
Discuss your application.
Tell us about your machine and what you need from a web guide. Only name, company, email and a short message are required. An engineer will be in touch to talk through your application. Or email admin@solveelectrical.co.nz.