Roll-to-roll machine and methods for repeatability and reproducibility of measurements

Abstract

Disclosed is a method for testing and / or operating a roll-to-roll machine comprising a floating unwinder and an edge position sensor attached thereto, and a floating rewinder with an edge position sensor attached thereto.

Description

[0001] The technical field generally concerns roll-to-roll machines and methods for repeatability and reproducibility.

[0002] A substrate can be moved from an unwinder roll to a rewinder roll of a roll-to-roll machine in a variety of processes that can be performed on the substrate while the substrate moves from the unwinder roll to a rewinder roll.

[0003] DE 699 03 903 T2 describes a friction drive device for feeding a strip material longitudinally along a transport path for printing, plotting, or cutting, which enables the alignment of the strip material, wherein the strip material has a first longitudinal side and a second longitudinal side. The friction drive device comprises a first friction wheel connected to the first longitudinal side of the strip material; a second friction wheel connected to the second longitudinal side of the strip material; a first motor drive for rotating the first friction wheel; a second motor drive for rotating the second friction wheel; and a first sensor for monitoring the lateral position of the strip material, wherein the first sensor is arranged behind the first and second friction wheels relative to the direction of movement of the strip material, characterized in that the first sensor generates a first sensor signal indicating the exact position of the strip material.and a processor independently controls the speed of the first motor drive and the speed of the second motor drive and receives the first sensor signal to automatically align the belt material relative to the transport path at the start of operation, wherein the processor controls the movement of the first and second friction wheels at different differential speeds in one direction by applying a differential signal that is essentially proportional to the lateral deflection of the belt material.

[0004] EP 4 520 695 A1 describes a winding and unwinding system comprising at least two winding rollers, a roller changing device, a detection device, a measuring device and a control unit.The roller changing device can drive the at least two winding rollers to move sequentially to a fixed position, and the winding roller at the fixed position can wind up a strip material; the sensing device sends a signal when the winding roller at the fixed position rotates one revolution; the measuring device measures the running length of the strip material; upon receiving the signal, the control device determines the winding diameter of the winding roller at the set position based on the running length measured by the measuring device; when the winding diameter reaches a preset threshold, the control system drives the roller changing device to drive the other winding roller to move to the set position and come into contact with the strip material, so that the strip material is wound onto the other winding roller.

[0005] Accordingly, the object of the present invention is to provide a roll-to-roll machine and a method for testing and / or operating a roll-to-roll machine that enables improved repeatability and reproducibility using the roll-to-roll machine.

[0006] The problem is solved by the subject matter of the independent claims.

[0007] Furthermore, other desirable features and characteristics of the patentable variations will become apparent from the following detailed description and the attached claims in conjunction with the attached drawings and the preceding introduction.

[0008] According to the invention, a method comprises the following: (a) moving a substrate with a plurality of sample locations identified on the substrate in a first longitudinal direction such that each sample location of the plurality of sample locations moves past a sensor; (b) holding the sensor in a constant position relative to a first side edge and a second side edge of the substrate while the plurality of sample locations moves past the sensor; (c) using the sensor to collect data regarding a property of the substrate at each sample location; (d) moving the substrate with the plurality of sample locations identified on the substrate in a second longitudinal direction opposite to the first longitudinal direction such that each sample location of the plurality of sample locations moves back past the sensor;and (e) repeating steps (ad), each sampling location of the plurality of sampling locations being identified by spaced-apart pieces of tape or markers.;

[0009] In one embodiment, the plurality of sample locations comprises at least five sample locations.

[0010] In one embodiment, the repeated execution of steps (ad) includes repeating steps (ad) eight times to collect fifty data points regarding the properties of the substrate.

[0011] In one embodiment, the sensor is designed and arranged to measure the thickness of the substrate.

[0012] In one embodiment, the substrate comprises a battery electrode material.

[0013] In one embodiment, the method further comprises moving the substrate laterally while the substrate moves in the first longitudinal direction.

[0014] In one embodiment, the battery electrode material comprises a metal foil.

[0015] In one application, the method may include: providing a roll-to-roll machine comprising a floating unwinder, comprising an unwinder drum and a linear unwinder actuator for moving the unwinder drum in a first lateral direction and a second lateral direction, an unwinder motor coupled to the unwinder drum to rotate the unwinder drum in a first direction of rotation and a second direction of rotation opposite to the first direction of rotation, a substrate of which a section is wound onto the unwinder drum, a first plurality of rollers for moving the substrate through the floating unwinder, a first edge position sensor attached to the floating unwinder for lateral movement with it, a feeder unit comprising a second plurality of rollers for moving the substrate through the feeder unit, and a second edge position sensor.which is attached to the feed unit, wherein the feed unit is stationary, a discharge unit comprising a third plurality of rollers for moving the substrate through the discharge unit, a third edge position sensor attached to the discharge unit, wherein the discharge unit is stationary, a floating rewinder comprising a rewinder drum and a linear rewinder actuator for moving the rewinder drum in the first lateral direction and the second lateral direction, a rewinder motor coupled to the rewinder drum to rotate the rewinder drum in the first direction of rotation and the second direction of rotation opposite to the first direction of rotation, wherein the substrate is wound onto the rewinder drum, wherein the floating rewinder comprises a fourth plurality of rollers for moving the substrate through the floating rewinder, a fourth edge position sensor,which is attached to the floating rewinder for lateral movement, an electronic control comprising an electronic processor, a non-volatile storage medium with instructions stored thereon and executable by the electronic processor, wherein the electronic control is operatively connected to the linear unwinder actuator, the first edge position sensor, the second edge position sensor, the third edge position sensor, the fourth edge position sensor, the linear unwinder actuator and the linear rewinder actuator; moving sections of the substrate from the floating unwinder to the floating rewinder, wherein the substrate passes through the first edge position sensor and the second edge position sensor, wherein the electronic control uses data from the second edge position sensor to determine a first location of the substrate as the substrate enters the feed unit,and sends a first command to the linear unwinder actuator to move the unwinder drum in the first lateral direction or the second lateral direction to position the substrate as the substrate enters the feed unit, the substrate passing through the discharge unit and the third edge position sensor and the fourth edge position sensor, and wherein the electronic control uses data from the fourth edge position sensor to determine a second location of the substrate as the substrate enters the floating rewinder, and wherein the electronic control sends a second command to the linear unwinder actuator to move the rewinder drum in the first lateral direction or the second lateral direction so that the substrate is wound onto the rewinder drum at a predetermined location on the rewinder drum; moving the substrate from the floating rewinder to the floating unwinder,wherein the substrate passes through the fourth edge position sensor and the third edge position sensor, wherein the electronic control uses data from the third edge position sensor to determine a third location of the substrate as the substrate enters the discharge unit, and sends a third command to the linear unwinder actuator to move the rewinder drum in the first lateral direction or the second lateral direction to adjust the substrate as the substrate enters the discharge unit, wherein the substrate passes through the feed unit and the second edge position sensor and the first edge position sensor, and wherein the electronic control uses data from the first edge position sensor to determine a fourth location of the substrate as the substrate enters the floating unwinder, and wherein the electronic control sends a fourth command to the linear unwinder actuator,to move the winding drum in the first lateral direction or the second lateral direction so that the substrate is wound onto the winding drum at a predetermined position.

[0016] In one embodiment, the substrate comprises a plurality of sample locations identified on the substrate in a first longitudinal direction, such that the plurality of sample locations moves past a sensor while sections of the substrate move from the floating unwinder to the floating rewinder.

[0017] In one embodiment, the method further comprises holding the sensor in a constant position relative to a first side edge and a second side edge of the substrate while the plurality of sample locations moves past the sensor.

[0018] In one embodiment, the plurality of sample locations comprises at least five sample locations.

[0019] In one embodiment, the sensor is designed and arranged to measure the thickness of the substrate.

[0020] In one embodiment, the substrate comprises a battery electrode material.

[0021] In one embodiment, each sample location of the plurality of sample locations is identified by spaced-apart strips or markings.

[0022] According to the invention, the present invention further comprises a system comprising: a roll-to-roll machine comprising a floating unwinder, comprising an unwinder drum and a linear unwinder actuator for moving the unwinder drum in a first lateral direction and a second lateral direction, an unwinder motor coupled to the unwinder drum to rotate the unwinder drum in a first direction of rotation and a second direction of rotation opposite to the first direction of rotation, a substrate of which a section is wound onto the unwinder drum, a first plurality of rollers for moving the substrate through the floating unwinder, a first edge position sensor attached to the floating unwinder for lateral movement therewith, a feeder unit comprising a second plurality of rollers for moving the substrate through the feeder unit, and a second edge position sensor.which is attached to the feed unit, wherein the feed unit is stationary, a discharge unit comprising a third plurality of rollers for moving the substrate through the discharge unit, a third edge position sensor attached to the discharge unit, wherein the discharge unit is stationary, a floating rewinder comprising a rewinder drum and a linear rewinder actuator for moving the rewinder drum in the first lateral direction and the second lateral direction, a rewinder motor coupled to the rewinder drum to rotate the rewinder drum in the first direction of rotation and the second direction of rotation opposite to the first direction of rotation, wherein the substrate is wound onto the rewinder drum, wherein the floating rewinder includes a fourth plurality of rollers for moving the substrate through the floating rewinder, a fourth edge position sensor,which is attached to the floating unwinder for lateral movement, an electronic control comprising an electronic processor, a non-volatile storage medium with instructions stored thereon and executable by the electronic processor, wherein the electronic control is operatively connected to the linear unwinder actuator, the first edge position sensor, the second edge position sensor, the third edge position sensor, the fourth edge position sensor, the linear unwinder actuator and the linear rewinder actuator; wherein the electronic control is configured to perform actions that include: moving sections of the substrate from the floating unwinder to the floating rewinder, the substrate passing through the first edge position sensor and the second edge position sensor, wherein the electronic control uses data from the second edge position sensor,to determine a first location of the substrate as the substrate enters the feed unit, and sends a first command to the linear unwinder actuator to move the unwinder drum in the first lateral direction or the second lateral direction to position the substrate as the substrate enters the feed unit, the substrate passing through the discharge unit and the third edge position sensor and the fourth edge position sensor, and wherein the electronic control uses data from the fourth edge position sensor to determine a second location of the substrate as the substrate enters the floating rewinder, and wherein the electronic control sends a second command to the linear unwinder actuator to move the rewinder drum in the first lateral direction or the second lateral direction,so that the substrate is wound onto the rewinder drum at a predetermined position on the rewinder drum; moving the substrate from the floating rewinder to the floating unwinder, the substrate passing through the fourth edge position sensor and the third edge position sensor, the electronic control using data from the third edge position sensor to determine a third location of the substrate as the substrate enters the discharge unit, and sending a third command to the linear unwinder actuator to move the rewinder drum in the first lateral direction or the second lateral direction to position the substrate as the substrate enters the discharge unit, the substrate passing through the feed unit and the second edge position sensor and the first edge position sensor, and the electronic control using data from the first edge position sensor,to determine a fourth location of the substrate as the substrate enters the floating unwinder, and wherein the electronic control sends a fourth command to the linear unwinder actuator to move the rewinder drum in the first lateral direction or the second lateral direction, so that the substrate is wound onto the rewinder drum at a predetermined location on the rewinder drum.

[0023] In one embodiment, the substrate comprises a plurality of sample locations identified on the substrate in a first longitudinal direction, such that the plurality of sample locations moves past a sensor while sections of the substrate move from the floating unwinder to the floating rewinder.

[0024] In one embodiment, the system further comprises holding the sensor in a constant position relative to a first side edge and a second side edge of the substrate while the plurality of sample locations moves past the sensor.

[0025] In one embodiment, the substrate comprises a battery electrode material.

[0026] In one embodiment, the substrate comprises a metal foil.

[0027] The illustrative variations are described below in conjunction with the following drawing figures, where the same reference symbols denote the same elements and where: Fig. 1 a schematic representation of a substrate with a multitude of sample locations that can be identified by a band or marker according to a number of variations; Fig. 2 a flowchart of a process that may involve detecting a large number of labeled locations on a substrate according to a number of variations; Fig. 3 a schematic representation of a section of a roll-to-roll machine with a floating unwinder or a floating rewinder according to a number of variations; Fig. 4 is a schematic representation of a section of a roll-to-roll machine with an unwinder and a feeder according to a number of variations; Fig. 5 is a schematic representation of a section of a roll-to-roll machine with a floating winder and an outlet unit according to a number of variations; Fig. 6 is a schematic representation of a roll-to-roll machine operated in a forward direction, the substrate moving from a floating unwinder to a floating rewinder according to a number of variations; Fig. 7 is a schematic representation of a roll-to-roll machine operated in a reverse direction, the substrate moving from a floating winder to a floating unwinder according to a number of variations; Fig. 8 is a schematic representation of a feed loop with an edge position sensor that provides data to an electronic control which can send a command to a lateral actuator according to a number of variations; Fig. 9A and Fig. 9B present a flowchart of a procedure that may involve detecting a large number of labeled locations on a substrate according to a number of variations.

[0028] The following detailed description is for illustrative purposes only and is not intended to limit applications and uses. Furthermore, there is no intention to be bound by any expressed or implied theory presented in the preceding introduction, the brief description of the drawings, the short summary, or the following detailed description.

[0029] With reference to Fig. 1. A product 30 can comprise a substrate 32 with a plurality of sample locations 1, 2, 3, 4, 5, each of the plurality of sample locations 1, 2, 3, 4, 5 being identifiable in a plurality of ways, including, but not limited to, the use of a pair of spaced-apart strips or markers 42. The substrate 32 can generally be flat and can have a first surface 34 and a second surface 36. The substrate 32 can have a first side edge 38 and a second side edge 40 opposite the first side edge 38. The substrate 32 can be moved in a first longitudinal direction 46 or a second longitudinal direction 48 opposite the first longitudinal direction 46.A sensor 44 can be used to determine a property of the substrate 32 and can be held in a constant position with respect to the first side edge 38 and the second side edge 40, for example, when the substrate 32 is moved in the first longitudinal direction 46. In a number of variations, the sensor 44 can be a property sensor, which can be a thickness gauge designed and arranged to measure the thickness of the substrate 32 at each of the sample locations 1, 2, 3, 4, 5. Data can be collected from the sensor 44 using an electronic control 96 for multiple passes of the substrate 32 moving in the first longitudinal direction 46. For example, the substrate 32 can be moved in the first longitudinal direction 46 such that each sample location 1, 2, 3, 4, 5 passes by the sensor 44.The substrate 32 can then be moved in the second longitudinal direction 48, so that each of the sample locations moves back past the sensor 44. The process can then be repeated several times. For example, the process can be repeated nine times to collect fifty substrate thickness measurements. Repeating the process to collect fifty thickness measurements can be used to verify a repeatability and reproducibility standard / requirement of type 3. Any of the thickness measurement sensors known to a person skilled in the art can be used to measure the thickness of the substrate.A thickness sensor typically works by measuring the distance between two surfaces of a material using a method such as laser triangulation, where a laser beam is projected onto the surface and the reflected light is analyzed to determine the distance, with the thickness being calculated by subtracting the distance to the upper surface from the distance to the lower surface. Often, two sensors positioned on opposite sides of the material are used to achieve this measurement. Other methods include capacitive sensing, where the change in capacitance between the sensors and the material is proportional to the thickness, or ultrasonic waves, where the time it takes for an ultrasonic pulse to travel through the material is used to calculate the thickness.

[0030] With reference to Fig. 2. A method may comprise a first step 50, which involves moving a substrate with a plurality of sample locations identified or marked on the substrate in a first longitudinal direction, such that the plurality of sample locations moves past a sensor. A second step 52 may involve maintaining the sensor position relative to the first side edge and a second side edge of the substrate while the plurality of sample locations moves past the sensor. A third step may involve using the sensor to collect data regarding a property of the substrate at each sample location of the plurality of sample locations. A fourth step may involve moving the substrate with a plurality of sample locations marked on the substrate in a second longitudinal direction opposite to the first direction, such that the plurality of sample locations moves back past the sensor.The first step 50, the second step 52, the third step 54, and the fourth step 56 can then be repeated numerous times in sequence. While the substrate 32 is moved in the first longitudinal direction 46, it can also move in a first lateral direction or a second lateral direction opposite to the first lateral direction. The sensor 44 is held in a constant position with respect to the first lateral edge 38 and the second lateral edge 40 of the substrate. Thus, the sensor 44 can be positioned to move with the substrate 32 if the substrate moves in the first lateral direction or the second lateral direction.

[0031] With reference to Fig. 3. A product 30, which may be a roll-to-roll machine, can comprise a floating unwinder 58, which may include a motor 60 with a shaft 62 rotatably driven by the motor 60. The shaft 62 can be coupled to an unwinder drum 64, onto which the substrate 32 can be wound or unwound. A linear unwinder actuator 68 can be coupled to the housing 66, enabling the unwinder drum 64 to move in a first lateral direction 70 and a second lateral direction 72, which is opposite to the first lateral direction 70. The linear unwinder actuator 68 can be of any type known to a person skilled in the art, including, but not limited to, a linear rack and pinion actuator or a linear ball screw actuator. Alternatively, the linear unwinder actuator 68 can be arranged to move the unwinder drum 64 and / or the shaft 62.The floating unwinder can be designed such that at least the unwinder drum 64 can move in the first lateral direction 70 and a second lateral direction 72 in response to data collected by edge position sensors that measure the location of the first lateral edge 38 and / or the second lateral edge 40 of the substrate 32 (in . Fig. (shown in Figures 6-7). During testing or operation of a roll-to-roll machine 31, the substrate 32 can move laterally, which would cause the substrate 32 to be wound telescopically onto the unwinder drum 64, an undesirable effect. Data from the edge position sensors can be used by an electronic controller to send commands to the linear unwinder actuator 68 to move the unwinder drum into a first lateral position or a second lateral position, so that the substrate 32 is wound properly onto the unwinder drum 64 and not telescopically. Furthermore, the linear unwinder actuator 68 can be used to position the substrate 32 in the correct position for the processing equipment to work on the substrate 32, which may include, but is not limited to, pressing the substrate 32 to a thickness within a predetermined range.

[0032] Fig. Figure 4 illustrates sections of a roll-to-roll machine 31 comprising a floating unwinder 58 and a feeder 80. The floating unwinder 58 may include a motor and a shaft (best in Fig. 3), an unwinder drum 64 with the substrate 32 wound on it. The floating unwinder 58 can include a housing 66 and an associated linear unwinder actuator 68. The floating unwinder 58 can include a first plurality of rollers 74 for guiding the path of the substrate 32 as it is unwound or wound onto the unwinder drum 64 of the floating unwinder 58. A first edge position sensor 76 is attached to the floating unwinder 58 and moves laterally with the floating unwinder 58. The first edge position sensor 76 is located along the first side edge 38 or the second side edge 40 (best in Fig. 3) of the substrate 32. The feed unit 80 may include a second set of rollers 82 for guiding the substrate 32. A second edge position sensor 78 may be connected to the feed unit 80. The feed unit 80 is or may be fixed to the base. The edge position sensor 78 and the feed unit 80 are fixed to each other and are not expected to move relative to each other. Both the first edge position sensor 76 and the second edge position sensor 78 may be positioned along the first side edge 38 or the second side edge 40 (preferably in Fig. (3 to be seen) of the substrate 32. The first edge position sensor 76 and the second edge position sensor 78 are positioned between the floating unwinder 58 and the feeder 80, with the first edge position sensor 76 being closer to the floating rewinder than the second edge position sensor 78.

[0033] Fig. Figure 5 illustrates sections of a roll-to-roll machine 31 comprising a discharge unit 84 and a floating rewinder 92. The discharge unit 84 may include a third set of rollers 86 for guiding the substrate 32. The discharge unit 88 is or may be fixed to the floor. A third edge position sensor 88 and the discharge unit 84 are fixed to each other and are not expected to move relative to each other. The floating rewinder 92 may be constructed similarly to the floating unwinder 58. The floating rewinder 92 may include a motor 60 and a shaft 62 (best in Fig. 3 to be seen), and a rewinder drum 65 with the substrate 32 wound on it. The floating rewinder 92 can include a housing 66 and an associated linear rewinder actuator 69. The floating rewinder 92 can include a fourth set of rollers 94 for guiding the path of the substrate 32 while the substrate 32 is unwound or wound onto the rewinder drum 65 of the floating rewinder 92. A fourth edge position sensor 90 is attached to the floating rewinder 92 and moves laterally with the floating rewinder 92. Both the third edge position sensor 88 and the fourth edge position sensor 90 can be positioned along the first side edge 38 or the second side edge 40 (best in Fig. 3) be positioned. The third edge position sensor 88 and the fourth edge position sensor 90 can be positioned between the floating rewinder 92 and the output unit 84, with the fourth edge position sensor 90 being closer to the floating rewinder 92 than the third edge position sensor 88.

[0034] With reference to Fig. 6. The product 30, which can be a roll-to-roll machine, can be operated such that the substrate 32 is moved in a first longitudinal direction 46 from the floating unwinder 58 to the floating rewinder 92. As the substrate 32 moves in the first longitudinal direction 46, the second edge position sensor 78, attached to the feeder 80, is used to measure the position of the substrate 32 in front of the feeder 80. Data from the first edge position sensor 76 could not be used when the substrate is being unwound from the floating unwinder 58. The substrate 32 moves past the second edge position sensor 78 through the feeder 80 and into the output unit 84, and then past the third edge position sensor 88. Data from the third edge position sensor 88 could not be used when the substrate is moving in the first longitudinal direction 46.The substrate 32 moves from the third edge position sensor 88 past the fourth edge position sensor 90. Data from the fourth edge position sensor is used to cause the linear rewinder actuator 69 of the floating rewinder 92 to move laterally in order to properly wind the substrate 32 onto the rewinder drum 65 of the floating rewinder 92 and to prevent telescopic winding of the substrate 32.

[0035] With reference to Fig. 7. The substrate 32 can be moved in a second longitudinal direction 48 from the floating winder 92 to the floating unwinder 58. The substrate 32 moves from the floating winder 92 through the fourth edge position sensor 90 and through the third edge position sensor 88. Data from the fourth edge position sensor 90 cannot be used while the substrate 32 is moving in the second longitudinal direction 48. Data from the third edge position sensor 88 is collected and used to determine the position of the substrate 32 as it enters the output unit 84. From the output unit 84, the substrate 32 moves into the feed unit 80. From the feed unit 80, the substrate 32 moves through the second edge position sensor 78 and through the first edge position sensor 76. Data from the second edge position sensor 78 cannot be collected while the substrate is moving in the second longitudinal direction 48.Data from the first edge position sensor 76 are used to cause the linear actuator of the floating unwinder 58 to move the drum in a lateral direction so that the substrate 32 is properly wound onto the unwinder drum 64, and to prevent telescopic winding of the substrate 32 onto the unwinder drum 64 of the floating unwinder 58.

[0036] With reference to Fig. 8 The first edge position sensor 76, the second edge position sensor 78, the third edge position sensor 88 and the fourth edge position sensor 90 can be operationally connected so that data can be transmitted to an electronic controller 96 and commands can be sent to the linear unwinder actuator 68 of the floating unwinder 58 or the linear rewinder actuator 69 of the floating rewinder 92 (best in Fig. (See Figures 6-7). An electronic control 96 may comprise an electronic processor 98 and a non-volatile, computer-readable medium 100 containing instructions 102 stored thereon, which can be executed by the electronic processor 98 to perform any of the actions or procedures disclosed herein.

[0037] Fig. 9A and Fig.Figure 9B illustrates a flowchart of a process that may include provisioning operation 120: provisioning a roll-to-roll machine comprising a floating unwinder, comprising an unwinder drum and a linear unwinder actuator for moving the unwinder drum in a first lateral direction and a second lateral direction, an unwinder motor coupled to the unwinder drum to rotate the unwinder drum in a first direction of rotation and a second direction of rotation opposite to the first direction of rotation, a substrate of which a section is wound onto the unwinder drum, a first plurality of rollers for moving the substrate through the floating unwinder, a first edge position sensor attached to the floating unwinder for lateral movement therewith, a feeder unit comprising a second plurality of rollers for moving the substrate through the feeder unit,a second edge position sensor attached to the feed unit, wherein the feed unit is stationary, a discharge unit comprising a third plurality of rollers for moving the substrate through the discharge unit, a third edge position sensor attached to the discharge unit, wherein the discharge unit is stationary, a floating rewinder comprising a rewinder drum and a linear rewinder actuator for moving the rewinder drum in the first lateral direction and the second lateral direction, a rewinder motor coupled to the rewinder drum to rotate the rewinder drum in the first direction of rotation and the second direction of rotation opposite to the first direction of rotation, wherein the substrate is wound onto the rewinder drum, wherein the floating rewinder includes a fourth plurality of rollers for moving the substrate through the floating rewinder, a fourth edge position sensor,which is attached to the floating rewinder for lateral movement, an electronic control comprising an electronic processor, a non-volatile storage medium with instructions stored thereon and executable by the electronic processor, wherein the electronic control is operatively connected to the linear unwinder actuator, the first edge position sensor, the second edge position sensor, the third edge position sensor, the fourth edge position sensor, the linear unwinder actuator and the linear rewinder actuator. Action 122: Moving sections of the substrate from the floating unwinder to the floating rewinder, wherein the substrate passes through the first edge position sensor and the second edge position sensor, wherein the electronic control uses data from the second edge position sensor to determine a first location of the substrate when the substrate enters the feed unit,and sends a first command to the linear unwinder actuator to move the unwinder drum in the first lateral direction or the second lateral direction to position the substrate as the substrate enters the feed unit, the substrate passing through the discharge unit and the third edge position sensor and the fourth edge position sensor, and wherein the electronic control uses data from the fourth edge position sensor to determine a second location of the substrate as the substrate enters the floating rewinder, and wherein the electronic control sends a second command to the linear rewinder actuator to move the rewinder drum in the first lateral direction or the second lateral direction,so that the substrate is wound onto the rewinder drum at a predetermined location on the rewinder drum. And Act 124: Moving the substrate from the floating rewinder to the floating unwinder, wherein the substrate passes through the fourth edge position sensor and the third edge position sensor, wherein the electronic control uses data from the third edge position sensor to determine a third location of the substrate when the substrate enters the discharge unit, and sends a third command to the linear rewinder actuator to move the rewinder drum in the first lateral direction or the second lateral direction to position the substrate when the substrate enters the discharge unit, wherein the substrate passes through the feed unit and the second edge position sensor and the first edge position sensor, and wherein the electronic control uses data from the first edge position sensor,to determine a fourth location of the substrate when the substrate enters the floating unwinder, and wherein the electronic control sends a fourth command to the linear unwinder actuator to move the rewinder drum in the first lateral direction or the second lateral direction, such that the substrate is wound onto the rewinder drum at a predetermined position on the rewinder drum.

[0038] Although at least one variation has been presented in the foregoing detailed description, it is understood that a large number of variations exist. It is also understood that the variation or variations are merely examples and are not intended to limit the scope, applicability, or configuration of the disclosure in any way. Rather, the foregoing detailed description provides the person skilled in the art with a suitable plan for implementing the illustrative variation or variations. It is understood that various modifications to the function and arrangement of elements can be made without deviating from the scope of the disclosure as set out in the attached claims and their legal equivalents.

Claims

[1] Procedure, encompassing: (a) Moving (50) a substrate (32) with a plurality of sample locations (1, 2, 3, 4, 5) identified on the substrate (32) in a first longitudinal direction (46) such that each sample location (1, 2, 3, 4, 5) of the plurality of sample locations (1, 2, 3, 4, 5) moves past a sensor (44); (b) Holding (52) the sensor (44) in a constant position relative to a first side edge (38) and a second side edge (40) of the substrate (32) while the plurality of sample locations (1, 2, 3, 4, 5) move past the sensor (44); (c) Using (54) the sensor (44) to collect data regarding a property of the substrate (32) at each sample location (1, 2, 3, 4, 5); (d) Moving (56) the substrate (32) with the plurality of sample locations (1, 2, 3, 4, 5) identified on the substrate in a second longitudinal direction (48) opposite to the first longitudinal direction (46), such that each sample location (1, 2, 3, 4, 5) of the plurality of sample locations (1, 2, 3, 4, 5) moves back past the sensor (44); and (e) Repeating steps (ad); wherein each sample location (1, 2, 3, 4, 5) of the plurality of sample locations (1, 2, 3, 4, 5) is identified by spaced-apart pieces of tape or markers (42). [2] Method according to claim 1, wherein the plurality of sample locations (1, 2, 3, 4, 5) comprises at least five sample locations. [3] Method according to claim 1, wherein the repeated steps (ad) comprise repeating the steps (ad) eight times to collect fifty data regarding the property of the substrate (32). [4] Method according to claim 1, wherein the sensor (44) is designed and arranged to measure a thickness of the substrate (32). [5] Method according to claim 4, wherein the substrate (32) comprises a battery electrode material. [6] Method according to claim 1, further comprising moving the substrate (32) laterally while the substrate (32) moves in the first longitudinal direction (46). [7] Method according to claim 5, wherein the battery electrode material comprises a metal foil. [8] System, comprehensive: a roll-to-roll machine (30, 31) comprising a floating unwinder (58), comprising an unwinder drum (64) and a linear unwinder actuator (68) for moving the unwinder drum (64) in a first lateral direction (70) and a second lateral direction (72), an unwinder motor (60) coupled to the unwinder drum (64) to rotate the unwinder drum (64) in a first direction of rotation and a second direction of rotation opposite to the first direction of rotation, a substrate of which a section is wound onto the unwinder drum, a first plurality of rollers (74) for moving the substrate (32) through the floating unwinder (58), a first edge position sensor (76) attached to the floating unwinder (58) for lateral movement therewith, a feeder unit (80) comprising a second plurality of rollers (82) for moving the substrate (32) through the feeder unit (80), and a second edge position sensor (78) attached to the feeder unit (80). is attached, wherein the feed unit (80) is stationary,a discharge unit (84) comprising a third plurality of rollers (86) for moving the substrate (32) through the discharge unit (84), a third edge position sensor (88) attached to the discharge unit (84), wherein the discharge unit (84) is stationary, a floating rewinder (92) comprising a rewinder drum (65) and a linear rewinder actuator (69) for moving the rewinder drum (65) in the first lateral direction (70) and the second lateral direction (72), a rewinder motor (60) coupled to the rewinder drum (65) to rotate the rewinder drum (65) in the first direction of rotation and in the second direction of rotation opposite to the first direction of rotation, wherein the substrate (32) is wound onto the rewinder drum (65), wherein the floating rewinder (92) comprises a fourth plurality of rollers (94) for moving the substrate (32) through the floating winder (92) includes a fourth edge position sensor (90),which is attached to the floating winder (92) for lateral movement, an electronic control unit (96) comprising an electronic processor (98), a non-volatile storage medium (100) with instructions (102) stored thereon and executable by the electronic processor (98), wherein the electronic control unit (96) is operationally connected to the linear unwinder actuator (68), the first edge position sensor (76), the second edge position sensor (78), the third edge position sensor (88), the fourth edge position sensor (90), the linear unwinder actuator (68) and the linear winder actuator (69); wherein the electronic control (96) is configured to perform actions which include the following: Moving sections of the substrate from the floating unwinder to the floating rewinder, with the substrate passing through the first edge position sensor and the second edge position sensor is running, with the electronic control using data from the second edge position sensor to determine a first location of the substrate, when the substrate enters the feed unit, and sends a first command to the linear unwinder actuator to move the unwinder drum in the first lateral direction or to move the substrate in the second lateral direction to position it as the substrate enters the feed unit, the substrate passing through the discharge unit and the third edge position sensor and the fourth edge position sensor, and the electronic control using data from the fourth edge position sensor to determine a second location of the substrate as the substrate enters the floating rewinder, and the electronic control sending a second command to the linear rewinder actuator to move the rewinder drum in the first lateral direction or the second lateral direction so that the substrate is wound onto the rewinder drum at a predetermined location on the rewinder drum; and Moving the substrate from the floating winder to the floating unwinder, the substrate passing through the fourth edge position sensor and the third edge position sensor, the electronic control using data from the third edge position sensor to determine a third location of the substrate when the substrate enters the discharge unit, and sending a third command to the linear winder actuator to move the winder drum in the first lateral direction or to move the substrate in the second lateral direction to adjust it as the substrate enters the discharge unit, the substrate passing through the feed unit and the second edge position sensor and the first edge position sensor, and the electronic control using data from the first edge position sensor to determine a fourth location of the substrate as the substrate enters the floating unwinder, and the electronic control sending a fourth command to the linear unwinder actuator to move the rewinder drum in the first lateral direction or to move in the second lateral direction so that the substrate is wound onto the unwinder drum at a predetermined position on the unwinder drum. [9] System according to claim 8, wherein the substrate (32) comprises a plurality of sample locations (1, 2, 3, 4, 5) identified on the substrate (32) in a first longitudinal direction (46), such that the plurality of sample locations (1, 2, 3, 4, 5) moves past a sensor while sections of the substrate (32) move from the floating unwinder (58) to the floating rewinder (92).

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