Software
Production-ready roll tracking software — built for industrial rewind and unwind operations with real-time dual encoder data
Production-ready roll tracking software — built for industrial rewind and unwind operations with real-time dual encoder data
Try the live RollTagger interface in your desktop browser — no sign-up required
Linear and rotary encoders sampled at 100 ms intervals for sub-millimetre position precision and live diameter calculation.
All data stored locally on the Revolution Pi — no cloud dependency, no internet required during production.
Rolls transfer automatically between rewinders, unwinders, and coating lines via .rtag file handoffs over the local network.
Automatic quality check at every 10-wind milestone comparing actual to expected position from the source rewind map.
Parent–child traceability across every production station from raw material inspection through final QC unwind.
REST API and machine I/O interfaces for connecting to upstream work order systems and downstream vision systems.
As material winds onto the roll, RollTagger records every millimetre. The physics engine uses dual encoder data to calculate real-time diameter, thickness, speed and rotation count — building a precise digital twin of the roll as it is created.
When a roll arrives at the unwinder, RollTagger loads the complete rewind map and plays it back against the live encoder feed. Position counts down from the recorded length to zero — and at every 10-wind milestone, the system verifies the material is exactly where it should be.
Wind verification status at each 10-wind checkpoint:
Every event tagged during rewind is stored with its precise position in metres, encoder counts, roll geometry, timestamp and operator notes. During unwind, these events drive automated machine actions — eliminating manual watching and reaction.
Every device in the network maintains its own Input, Output, and Backlog queue. Rolls move through the production chain automatically — from rewinder to coating line to unwinder — with full audit trail at every step.
Rolls transferred from other devices or imported from .rtag files, ordered FIFO and auto-pulled on session start.
Completed rewinds ready for transfer. Consumed unwinds kept read-only for audit. Auto-transfer to first paired device.
Historical archive with configurable retention (default 90 days). Re-pull rolls for reprocessing if needed.
Every roll carries its complete history as it moves through the plant. The .rtag file format bundles session data, events, measurements and lineage into a validated ZIP archive that transfers between devices without losing a single data point.
RollTagger runs entirely on the Revolution Pi Connect 4 mounted at the machine. There is no cloud account to manage, no internet dependency during production, and no data leaving the plant unless you choose to export it.