Tension Control Systems for Light, Medium, and Heavy-Duty Tensioning

Warner Electric Founded in 1927, Warner Electric has grown to become a global leader in the development of innovative electromagnetic clutch & brake solutions. Warner Electric engineers utilize the latest materials and manufacturing technologies to design long life, easy-to-use clutches and brakes that provide improved accuracy and repeatability. Warner Electric offers the broadest selection of industrial clutches, brakes, controls and web tension systems available from a single manufacturer. Reliable Warner Electric components are used in a wide range of markets including material handling,...

Contents Warner Electric Tension Control Systems Warner Electric offers the most complete line of tensioning products available. Several different types of electric and pneumatic brakes designed specifically for tension applications range in torque ratings from 1 oz.in. through 1785 lb.ft. Controls vary from simple manual adjust models through sophisticated closed loop dancer systems. Whether tensioning wire, film, foil, paper, kraft stock, or steel, Warner Electric offers the right tension system for your application. Let our tension specialists help you design the ideal system for your needs....

Analog Controls Modular Control Units ■ Input: 115/230 VAC, 50/60 Hz 47. ■ Output: 0-24 VDC ^ste^e 5.8 amps ■ Input 24-28 VDC @ 3 amps BXCTRL Web Tension Control The BXCTRL Web Tension Control is a solid state electronic control that receives a signal from dancer input sensors or two load cells (customer supplied). It integrates two separate Digital PID Controllers and two separate Open Loop controls. ■ All set-up is done via SD card or computer ■ When wired to dancer feedback, provides closed loop control with linear or auto compensation ■ Easily integrated with BX2DRV driver for electric...

Dancer Controls Power Supplies MCS-203 Dancer Control The MCS-203 automatically controls web tension through a dancer roll and sensor. It has 24 VDC output for use with TB, ATTB & ATTC, and Magnetic Particle clutches and brakes. See page 49. ■ Operates two 24 VDC tension brakes in parallel when using dual MCS-166 power supplies ■ Full P-I-D loop adjustment and system gain adjustment for optimum control. ■ Available in panel mount or enclosed wall/ shelf mount enclosure. TCS-210 Dancer Control The TCS-210 automatically controls web tension through a dancer roll and position sensor. It outputs...

Electric Brakes & Clutches Pneumatic Brakes & Clutches TB Series Basic Tension Annular style 24 VDC tension brakes for light to medium duty unwind tension applications. ■ Sizes: 1.7” to 15.25” diameter ■ Torque range: 0.50 lb.ft. to 256 lb.ft. ■ Thermal range: .019 HP to 1.09 HP ATT Series Advanced Technology Designed for intermediate web tension ranges. Three size ranges. ■ One piece clutch design for easy shaft mounting ■ Brakes are flange mounted and the armature is the only rotating member ■ Clutch torque ranges 7 to 41 lb.ft. Brake torque ranges from 8 to 62 lb.ft. ■ Replaceable friction...

Warner ElectricProducts for Controlling Tension Ultrasonic Sensors ■ Analog outputs with selectable 0-1OV - 4-20mA ■ Input voltage 20-30VDC ■ Range control zero and span ■ Short circuit protected ■ 80” max. distance ■ Response time 50 mSec Pivot Point Sensors The TCS-605-1 and TCS-605-5 pivot point sensors close the feed back loop to the tension control by sensing dancer roll position. ■ TCS-605-1 is a single turn potentiometer with a resistance of 1 KQ for normal dancer operating ranges within 60° of arm rotation. ■ TCS-605-2 is a single-turn potentiometer with a resistance of 5KQ for normal...

Tension Control Systems Application Examples Dancer Control The dancer control system consists of a power supply, ­ dancer control, pivot point sensor, and controlling ­ lement, ­ e i.e., tension brake or clutch. Dancers provide the web t ­ension while the control and controlling element stabilize dancer operation for unwind, intermediate zone or rewind tension. Pivot Point Sensor Analog Control The analog system consists of a control module, power supply, and a controlling element, i.e., tension brake or clutch. The analog controller provides output proportional to the input signal for use in...

Tension Control Systems Application Examples Dual Brake Unwind Dual brake unwind incorporates modular tension brakes and an analog control system. The brakes retard the unwind roll, creating tension in the web. An external, customer-provided signal adjusts the output current to the brakes to maintain the proper tension. The dual channel controller controls each brake ­ independently or simultaneously. Analog Signal Single Roll Magnetic Particle Brake Unwind The magnetic particle brake retards the unwind roll, maintaining ­ tension provided by the dancer roll’s weight. The pivot point sensor ­...

Tension Control Systems System Configurations Technical Considerations – Tension Zones I. A tension zone in a web processing machine is defined as that area between which the web is captured, or isolated. Virtually any machine can be broken down into tension zones, and it is important to do so to properly address maintaining the tension required. Simple machines, such as rewinders or inspection machines, may have only one zone (see Fig. 1). The primary goal here is to control tension so that the rewound package is accurately wound. Typically, the winder (A) would be a simple line speed motor...

Flying Splicer Specially designed solid state splicer control holds the unused roll stationary while tensioning the operating roll. Dancer variation sensing and subsequent adjustment are virtually instantaneous for accurate tensioning during the splice typically at less than 1% variation. Reliable and accurate control for all system design layouts Open loop tension control systems provide the least expensive manner to provide a degree of web tension control with the minimal amount of components. Open loop tension control can apply to unwind, intermediate, or rewind tension applications. Although...