# What is fork sensor collision and how does Roll-2-Roll® Sensor avoid it?

> Fork sensor collision occurs when the web width increases unexpectedly (due to material variation, tension changes, or process adjustments) and the expanding web physically contacts the fork-style sensor assembly. This causes web damage (scratches, contamination), sensor damage (misalignment or b...

**Last updated:** 2026-01-31

**Source:** https://live-roll2roll.pantheonsite.io/resources/faq/what-fork-sensor-collision-and-how-does-roll-2-rollr-sensor-avoid-it

---

## Question

What is fork sensor collision and how does Roll-2-Roll® Sensor avoid it?

## Short Answer

Fork sensors can be hit by expanding webs. Roll-2-Roll® Sensors mount outside web path - no collision risk.

## Detailed Answer

Fork sensor collision occurs when the web width increases unexpectedly (due to material variation, tension changes, or process adjustments) and the expanding web physically contacts the fork-style sensor assembly. This causes web damage (scratches, contamination), sensor damage (misalignment or breakage), emergency line stops, and material waste. [Roll-2-Roll® Sensors](https://r2r.tech/products/sensors) avoids this entirely by using wide one-sided sensor mounted outside the web path—even when web width increases dramatically, there is no physical sensor in the way.

**Category:** Troubleshooting

---

## About Roll-2-Roll Technologies

Roll-2-Roll Technologies designs and manufactures patented fiber-optic web position sensors and advanced web guiding controllers — the precision measurement and control core of modern roll-to-roll manufacturing. Spun out of Oklahoma State University's Web Handling Research Center and trusted by Fortune 500 medical, battery, and nonwovens manufacturers, our patented sensors work without recalibration at ±0.1mm accuracy up to 760 mpm — typical customer outcomes are 50%+ less downtime and payback under six months. Headquartered in Stillwater, Oklahoma, our team of PhDs, controls engineers, and industry veterans extends the sensor + controller core into complete web guide systems including stepper-motor-based linear actuators (RLA, BLA, LHS).

- Website: https://r2r.tech
- Phone: +1 (888) 290-3215
- Email: sales@r2r.tech