Web Tension & Guiding Tension measurement and control
W
hen TTS Systems started manufacturing web tension loadcells back in the 1990’s the world was a diff erent place, the
internet was in its infancy, we relied on technical printed data sheets and drawings, and AI was something from science fi ction! But we still must remember the first principles of measurement. Good clean data to start with is essential for good control further down the line, which in turn means improved product quality, higher production speeds and reduced material waste.
We recently worked with a customer on the design and build of a compact machine to slit onto multiple rewinds with variable product widths. As the base material was a high specifi cation / cost product, which is only manufactured in low volumes, set up and adjustment waste was a major concern. We measured web tension at three key points on the machine, whilst remembering the following: • Firstly, measure the tension as close as possible to the key production area
• Ensure that you have suffi cient wrap angle on the roller
• Keep the loadcell cables as short as possible to the amplifi er
The single ended strain gauge loadcell with a large roller diameter, so as not to damage the product, was used to measure unwind tension, then again after the coating process and fi nally at the rewind after slitting. The loadcell amplifi ers output to the PLC was via Modbus, making communications simple.
The project also included a web guide from our partners at Roll-2-Roll to ensure the correct alignment to the outside edge, but also to verify the cut tape width after slitting. As this was a compact machine, we had to get the ODC192 line sensor as close to the slitters as possible. This was made easy as it’s a single sided sensor that uses plug and play technology, therefore it
does not need to be taught a new material i.e. it ignores material colour, fi nish and transparency or opaqueness. In addition, the sensor had a measurement line range of 192mm, so adjustment at the start of new batch run was not necessary. Now the SCU6x controller can work with two sensors and utilises Ethernet IP for high-speed communication.
WE ALWAYS START EVERY PROJECT WITH A CLEAN SHEET OF PAPER BUT NEVER FORGET THE BASICS!
Our products are UK manufactured and extensively used with paper, foil, fi lm, tape, plastics, rubber, in fact any material on a roll or reel that is processed through an automated machine can have its tension measured and controlled. When used in a closed loop control system, the measured signals can be used to regulate the speed of the drive, brake or clutch, thereby ensuring constant material tension throughout the process.
Working with System Builders, OEMs and End Users we provide knowledge, technical support and back-up to our UK and European customers through our direct staff and distribution partners.
30
September 2025
www.convertermag.com
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