Test & measurement
density that is four times lower than that of ABB’s Stressometer, reducing overall precision and responsiveness. Furthermore, unlike Stressometer technology which automatically compensates for external disturbances, piezoelectric sensors must correct for these factors via software, which is inherently less accurate.
The construction of piezoelectric sensors also poses issues, as the ceramic sensing element is housed in a metal body, which expands or contracts with temperature changes while the sensor element remains largely unaffected. This mismatch can introduce further errors unless meticulously compensated for, adding complexity and reducing performance. By contrast, air bearing sensors rely on rings riding or rotating on a cushion of pressurised air for measurement of differential pressure. While they provide good measurement performance, their reliance on compressed air and associated infrastructure can affect system design and maintenance planning, as well as increasing energy costs.
A CHALLENGING ENVIRONMENT FOR FORCE SENSING SYSTEMS Like a fragile sheet of tissue paper, ultra-thin foils are vulnerable to small changes in tension or pressure as they are subjected to multiple rolling passes. Breakage of the delicate metal strip due to microscopic material defects will bring production to an abrupt standstill or cause significant product quality deterioration. Even the smallest deviations from tightly specified foil parameters means line stops and lost production time, plus profit-sapping wastage of rejected material or re-processing. Further challenges are also often introduced by environmental conditions at the rolling plant. Temperature variations and mechanical vibrations can cause drift in the sensors used to measure roll thickness and tension, progressively undermining measurement accuracy. Typically, this is addressed by regular sensor recalibration – a labour- intensive task that inevitably means more process downtime – or software compensation and filtering of electrical signals. Added to these challenges is the limited installation space in modern rolling mills, which restricts the use of large or complex sensor assemblies. To address these issues, accurate low-force sensing is a critical enabler for precise monitoring and control of foil flatness
and thickness. Even the smallest material inconsistency or defects can have abrupt and often costly consequences, placing even greater importance on the reliability and accuracy of the force measurement and control system.
SPECIALISED LOW-FORCE SOLUTION MEETS THE DEMANDS OF ULTRA-THIN FOIL PRODUCTION
Reliable and repeatable measurement is made easier with the use of specialised low-force sensors that can detect extremely small variations in rolling force and/or strip tension to within a few grams. By capturing high-resolution force data in real time, modern sensing systems enable immediate correction of rolling parameters. With the latest solutions such as ABB’s next-generation low-force system, for example, it is possible to achieve unprecedented control of thickness and flatness control in finishing applications handling foil gauges ranging from 50 down to 5 microns where standard systems based on piezo- electric or air-bearing technology can suffer from noise or drift.
Featuring proven Pressductor technology, ABB’s Stressometer Low-Force System is an effectively maintenance-free solution that’s immune to process and ambient variation of parameters like strip tension and temperature. With no need for regular recalibration, the system can operate for extended periods with little or no intervention, further
contributing to optimised yields and reduced ownership costs.
ACHIEVING CONSISTENT QUALITY AND GREATER PROFITABILITY
By enabling tighter and more confident control of cold rolling processes, today’s low-force sensing solutions allow ultra-thin and speciality metal foil producers to ensure their products consistently meet the requirements of a competitive global market for high-performance electronic devices and other applications.
Accurate, consistent force measurement in the micron range during cold rolling supports product quality and production efficiency, reducing defect rates and optimising throughput by reducing costly stoppages caused by the breakage of delicate foils. Using the latest-generation sensing and control solutions also afford metal producers the opportunity boost their profitability, with reduced manual labour overheads and greater energy efficiency compared with conventional low-force measurement solutions.
ABB
www.abb.com
Instrumentation Monthly June 2026
41
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