Force measurement
FORCE MEASUREMENT A
ccurate force measurement is mission- critical in industries such as paper or metals, where maintaining the correct web tension can make the difference between enjoying a smooth-running operation and experiencing costly disruptions. When paper mills are churning out upwards of a kilometre of tissue every minute, any tear in the tissue can be potentially catastrophic.
At the same time, working in a hostile industrial environment is tough for instrumentation, making it tricky for load cells to deliver accurate tension measurements consistently over time. Choosing the right measurement technology can therefore make an enormous difference and solves some the biggest challenges faced by operators.
MAINTAIN LONG-TERM RELIABILITY Even if a load cell reports accurately when it is first installed, output signals are frequently subject to drift or instability over time. In fact, such problems are so common that an inability to trust load cell data is often cited as one of the biggest bugbears for users looking to monitor web tension.
Traditional tension measurement systems such as strain gauges or sensors based on linear variable differential transformer (LVDT) technology rely on a repeatable physical movement – bending or stretching - to generate an electrical signal. However, this makes these systems vulnerable to failure under challenging conditions.
In contrast, ABB’s Pressductor systems rely on the magnetic properties of certain steels to produce a signal in response to the force applied – a.k.a. the magnetoelastic effect. All ABB Pressductor load cells are based on this principle. With no movement required, these systems are much more durable and reliable over time than alternative technologies.
PROTECT AGAINST OVERLOADS In paper mills, tension must be maintained within tight margins to protect the web, including during emergency stops or other situations where a sudden acceleration or deceleration makes overloads more likely. Pressductor systems can withstand overloads of between three and ten times the nominal cell capacity, depending on the type of load cell. In contrast, shocks of that magnitude can destroy other instruments, or at least throw the calibration off. The everyday vibrations and temperature variations of normal mill operations are no problem in comparison.
WITHSTAND TOUGH CONDITIONS The tough industrial conditions commonly encountered in industries such as paper and metals are challenging for instrumentation. The typical atmosphere is hot, humid, and contaminated with particulates. Instruments are also subject to vibration
14 A TOUGH JOB DEMANDS THE
TOUGHEST TECHNOLOGY Jo Kirkbride, ABB Measurement and Analytics product manager UK and Ireland explains how choosing the right web tension measurement systems overcomes some of the most common challenges experienced by operators in industries such as paper and metals.
and electrical interference, meaning that equipment that works fine in the lab can often struggle, with electronics and moving parts all vulnerable to the surrounding hostile environment. While it is true that any instrument can be compromised if moisture or fumes get inside the cables and electronics, Pressductor gauges are less vulnerable to contamination and corrosion than other load cells. That is because rival technologies rely on movement within the transducer, so anything that restricts free movement can prevent them from functioning normally. For example, the mechanical stops used as overload protection in alternative gauges could become obstructed. The measurement signal is also exceptionally strong with magnetoelastic transducers, which makes Pressductor gauges exceptionally resilient in the face of electrical interference. Induced currents in signal cabling have long been a source of interference. However, the rapid proliferation of wireless devices across industry adds another possible culprit into the mix, thanks to the barrage of wireless signals passing to and fro.
Even Pressductor systems are not entirely bullet- proof and must be correctly installed to maintain consistent web tension measurement on an ongoing basis. Yet deploy them with care and they will consistently deliver a level of resilience that is hard to beat.
MAXIMISE UPTIME, CONTROL COSTS Greater durability and reduced calibration requirements enable web tension systems based on Pressductor technology to significantly reduce both planned and unplanned downtime in a typical paper mill or steel plant. This can deliver significant savings. While optimised uptime and trouble-free production usually accounts for the lion’s share of cost savings, the robust construction and reliable performance of Pressductor gauges also reduce the maintenance costs directly associated with the web tension measurement systems. This typically results in a lower total cost of ownership (TCO) over the lifetime of these load cells, compared to competing technologies.
BUILDING ON A HISTORY OF SUCCESS ABB’s Pressductor load cell technology first hit the industrial market 70 years ago. Fast forward to today, and these load cells can be found everywhere, companies are relying on tension measurement to optimise the production of strips and webs. While there have been upgrades and tweaks to the technology in the intervening decades, it is still clear that magnetoelastic gauges continue to deliver significant improvements in all-round performance when compared to the alternatives for measuring web tension.
ABB
www.abb.com September 2025 Instrumentation Monthly
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