Web Tension & Guiding
Web tension for measurement and control
By John Tyrrell, managing director, Total Tension Solutions
TS Systems has been producing web tension loadcells, instrumentation and controllers since the early 1990’s – in fact the company was formed to solve specifi c customer needs. Over the years we have continued to develop new ideas and solutions using the latest technology and manufacturing techniques. Why measure and control tension… It will improve product quality, production speed and reduce material waste.
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However, even today, we must remember the basics – rubbish data in, means rubbish data out to the controller! • Firstly, measure the tension as close as possible to the key production area or rewind / unwind
• Ensure that you have suffi cient wrap angle on the roller
• Keep the loadcell cables as short as possible to the amplifi er
The same rules apply for a new design or a retro fi t,
fi nding the best place to site your tension loadcells is key. As is knowing the expected material tension, ideally you want your tension load to be around 50 per cent of the total capacity of the loadcells. Our CRL and CRF loadcells have built in overload protection, as well as a fl oating bearing head to allow for some misalignment and end drift of the roller. The wrap angle is also important, the golden rule is at least 60 degrees, but more is always better. It is also worth remembering the eff ects of gravity and the roller dead weight, if the wrap is below the roller, then you are lifting against gravity and roller dead weight. Wherever possible, across the top is your best option. Loadcell cables should be as short as possible –
but the same length from each loadcell! We would recommend cable lengths up to 10m, with good earth / screening at the amplifi er.
Now what to do with the loadcell outputs, the DCA-22 is a dual channel loadcell amplifi er – i.e. we treat the left and right loadcells as individual inputs, amplify them individually and then digitally sum them to give a Total Tension Output as either 0 to 10VDC or 4 to 20mA, we also provide the individual 0 to 10VDC outputs for Tension Left and Tension Right – useful for alignment setup and fault fi nding. The analogue tension outputs can either be connected to your PLC system to give the machine control, or to a standalone tension controller to link to your drive or braking systems. Today our customers are about 50 / 50 on which control solution they choose, we can help with both.
So, you have your Tension Measurement and Control system designed, the installation and alignment of the loadcells with rollers is very important to save the loadcell bearing head and quality of measured tension. Also, do not forget calibration of the tension loadcells and amplifier – there are some very simple
techniques that still work well today! 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 2026
www.convertermag.com
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