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WARNER ELECTRIC
Tension Control Systems

Tension Control Systems

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Tension Control Systems

Product catalog summary

System Configurations

System Configuration 1: This configuration focuses on unwinding with a single tension zone (A-B), utilizing variable roll rotation speed and inertia to maintain constant tension, with an applicable brake system.
System Configuration 2: Involves single roll unwinding with two separate tension areas (X and Y), incorporating an unwinding brake, a motor for speed, and a clutch or motor-reducer for rewinding.
System Configuration 3: Describes a complex machine with intermediary tension areas, using a master-slave system to manage speed differences and maintain required tension.

Tension Control in Open Loop

Manual Setting by Potentiometer: Suitable for low-cost solutions with manual operator intervention, involving manual torque setting using a potentiometer.
Automatic Setting by Diameter Reading: Utilizes ultrasonic sensors for automatic torque adjustment based on roll diameter, eliminating operator intervention.

Tension Control in Closed Loop

Single Roll Tension Control: Uses a dancer arm for automatic tension adjustment, suitable for systems requiring precise tension control.
Double Roll Tension Control: Employs load cells or dancer arms for tension regulation, adaptable for modular or compact systems.

Brakes and Clutches Range

Electromagnetic Brake Type TB: Details sizing and characteristics for various applications, including strapping machines.
Magnetic Particle Clutches and Brakes: Covers MPB, MPC, BB, and BC series, highlighting applications and specifications.

Data Application Form

Includes tension selection criteria and a form for data application, emphasizing accurate tension zone definition and speed point identification.

Important Considerations

Emphasizes the need for clear identification of speed points and the role of tension control systems as slave to the machine's master speed setting.

Specifications
The document outlines specifications for Warner Electric's BTCS252 series switching power supply units, designed for industrial applications requiring safety, ease of use, and reliability. These units operate with an input of 90-264 VAC / 110 VDC at 50/60 Hz and output 24 VDC at 3 A (BTCS252) and 5 A (BTCS255). They comply with the Low Voltage Directive and EMI standards, ensuring high reliability and protection against incidental contacts (IP 20).

Applications and Advantages
The BTCS251 digital controller is suitable for use in unwinders, printing machines, and applications requiring intermittent or continuous function. It is particularly adapted for powder brakes, offering advantages such as PWM output, digital inputs, and microprocessor-based numeric control. The controller can manage motor or pneumatic brakes and features a simple installation process.

Control Systems
The document describes various control systems, including the BTCS251 for numeric control with microprocessor integration, and the HMCS202 for analogue control with fixed PID terms. The HMCS2000 series offers advanced features for double tension control in closed loop systems, with options for modular and compact configurations. These systems are designed for applications like printing machines and slitter, sheeter, and coater operations.

Technical Characteristics
The HMCS202 control system is based on classical PID terms, with adjustable loop gain and torque offset settings. The HMCS605-E2 rotary sensor is highlighted for its rugged housing and built-in switch for signal output polarity changes. The HMCS2000 series controllers offer digital control with features like automatic sensor scaling, programmable output configuration, and RS232 communication.

Load Cells
The document also covers foot-mounted load cells, available in versions with or without an incorporated amplifier. These load cells are suitable for retrofitting machines or heavy tension measurement, with various models offering different nominal load capacities.

Specifications:
The HMCS2000-IS Load Cell Interface is designed to sum and amplify input signals from two load cells. It requires an input supply of +24 VDC, ±10%, 300 mA. The interface supports analog inputs from load cells with voltages between 20 mV and 10 VDC, and ultrasonic inputs of 0-10 VDC. It provides calibrated outputs of 0-10 VDC, with a maximum gain of 1000.

Load Cell Features:
End shaft load cells, based on the Wheatstone bridge principle, are used for measuring web tension. They require careful installation to avoid vibrations and ensure accurate measurements. The load cells should not be oversized, with a recommended maximum factor of 1.5.

Mounting Recommendations:
Load cells should be installed in vibration-free locations with balanced sensing shafts. A minimum wrapping angle of 180° is recommended, and the load cell should be used in compression where possible.

Tension Brakes and Clutches:
The document details various series of tension brakes and clutches, including electromagnetic and magnetic particle types. Selection is based on maximum torque and thermal power dissipation requirements. The TB brake series is highlighted for its ability to handle short periods of high voltage during machine deceleration or emergency stops.

Magnetic Particle Clutches and Brakes:
These units offer precise torque control independent of slip speed, making them ideal for tension control and load simulation. They feature a compact design with no wearing parts, ensuring long life and efficient operation.

Selection and Sizing:
Proper sizing of magnetic particle clutches or brakes involves considering thermal energy and torque. The document provides formulas for calculating slip watts in continuous and cycling applications to ensure the heat input remains within the unit's dissipation rating.

Overview: The document provides detailed technical specifications and applications for Warner Electric Precision Tork™ magnetic particle clutches and brakes. These devices are used for controlling and maintaining torque in various industrial applications.

Specifications: The document outlines the torque calculation formulas for different applications, including soft/controlled stopping and tensioning. It provides quick selection charts for different models based on torque and slip RPM, along with maximum heat dissipation values.

Applications: Magnetic particle clutches and brakes are ideal for applications such as wire processing, paper/foil/film processing, labeling, textile processing, load profile simulation, life testing on motors and gears, conveyors, and bottle capping. They offer smooth controlled torque for tensioning in both unwind and rewind zones.

Technical Data: The document includes detailed tables with specifications for various models of magnetic particle clutches and brakes, including maximum torque, rated voltage, resistance, response time, inertia, and weight. It also provides dimensions and mounting specifications for each model.

Operating Characteristics: The torque transmitted by these units is proportional to the field current and is infinitely variable. The units can sustain continuous slip at a precise and stable torque value, independent of speed or slip speed. The document emphasizes the importance of mounting the units horizontally for optimal performance.

Selection Guidelines: For continuous slip applications, such as tension control in unwind or rewind applications, the document provides formulas for calculating slip watts. It also offers guidance on selecting the appropriate clutch or brake model based on application requirements.

Specifications: The document outlines the specifications for various models of magnetic particle brakes and clutches. A critical specification across all models is that the operating temperature must not exceed 70°C. The document provides detailed measurements for mounting and installation, including dimensions and bolt patterns.

Models and Performance: The document lists multiple models such as BBR65-1, BBV65-1, BB120-1, BBR120-1, BBV120-1, BB170-1, and others. Each model is described with its resistance at 20°C, power dissipation, weight, maximum torque, residual torque, voltage, and current. For instance, the BBR65-1 and BBV65-1 models have a maximum torque of 65 Nm and a residual torque of 0.4 Nm.

Magnetic Particle Clutches: Models such as BC12, BCR12, BC35, BCR35, BC65-1, and BCR65-1 are detailed with specifications including maximum torque, residual torque, voltage, current, resistance, power dissipation at different RPMs, and weight. The document emphasizes the importance of maintaining the operating temperature below 70°C.

Features and Benefits: The document highlights the benefits of using Precision Tork™ units, which provide constant torque independent of slip speed, offer overload and jam protection, and require no external control or power source. They are easy to install and provide long life with minimal maintenance.

Special Applications: The document mentions the availability of special applications such as special shaft bores, keyways, shaft extensions, and system retrofits.

Magnetic Brakes - MB Series: The document provides specifications for the MB series, including models like MB1M-5, MB2M-6, MB3M-8, and others. Each model is described with its maximum torque, heat dissipation, inertia, bending moment, maximum speed, and weight. The document also includes dimensions and mounting details.

Catalog excerpts

Tension Control Systems

Open the catalog to page 1

ABOUT THIS CATALOGUE This master catalogue groups all the solutions / products that WARNER ELECTRIC offers. An important part is dedicated to the solution design with particular consideration regarding the machine and the tension control installed. This should help you for the right solution choice taking in consideration the results you want to achieve. All the product characteristics and dimensions are included for every product. WARNER ELECTRIC offers the most complete product line dedicated to the TENSION CONTROL MARKET. The long experience in the market led us to develop high performance...

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Open loop solutions 6 Closed loop solutions 7 TENSION CONTROL IN OPEN LOOP 8 I.b - Manual setting by following arm 8 - 9 II - Automatic setting by diameter reading 10-11 III - Automatic setting by diameter reading with additional functions 12-15 TENSION CONTROL IN CLOSED LOOP 16 I - Single roll tension control, automatic setting by dancer arm 16 - 21 II - Double roll tension control, automatic setting by dancer arm (modular) 22 - 23 III - Double roll or splicer tension control, automatic setting by dancer arm (compact) 24 - 25 IV - Double...

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System configurations Analysing and preparing a project in tension control requires good analysis support. The general block diagrams below are a good representation of any machine generally supporting tension control. We recommend using these diagrams or a part of it in any discussion and correspondence in order to be clear and to avoid possible misunderstandings. The tension area in an unwinding system is defined by places where we want to control this tension SYSTEM CONFIGURATION 1 In single roll unwinding, we have one area tension between A and B. One brake can be easy installed in A. The...

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System configurations SYSTEM CONFIGURATION 3 More complicated machine with intermediary tension area between winder and unwinder.The intermediary area give the line speed. A master-slave system with speed difference in area B/C give required tension. All tension systems must be according the speed line in close loop. IMPORTANT CONSIDERATION ZONE 2*, Typical characteristics In every machine the speed point location must be clearly identified. In general one of driving nip roll is choose to set the linear speed. The machine speed is considered as MASTER function. The tension control, whatever the...

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System configurations OPEN LOOP CONFIGURATION Working in open loop requires an external reference setting applied to the driver. The torque applied to the unwind roll has to vary according to the diameter of the roll. We don’t control acceleration, deceleration and emergency stop as the sensor is blind regarding the band tension. Application needs one sensor only which drives an amplifier without return information for the influence of correction. OPEN LOOP SOLUTION Manual setting by pot. Amplifier Manual setting by following arm 8 9 Amplifier Automatic setting by diameter reading 10 11 Ultrasonic...

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System configurations CLOSED LOOP CONFIGURATION Working in close loop needs one sensor. This one will measure directly or indirectly the band tension. Tension variations detected by sensor are sent to the brake through the control. This action corrects the variation and the new corrected sensor value is sent to the brake and so on. Give a accurate tension regulation during acceleration, deceleration, emergency stop. Sensor Position regulation by dancer arm This is an electromechanical system and the building quality for the dancer arm must be verified. The band tension is created by the roll...

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Working in open loop requires that a torque setting is defined. The choice depends on the machine complexity and the automation required. One important factor that remains is the tension precision. For unwind and rewind systems the diameter ratio will play an important role. Working in open loop also requires special considerations regarding system inertia.

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Potentiometer BTCS254 With strong housing and axis with bearing, the potentiometer BTCS254 is suitable for open or closed loop applications. BTCS254-06 BTCS254-10 Potentiometer Shaft material Cover material Body material Protection Operating temperature Cable length Weight Service manual 6 mm axis 10 mm axis 10 k Ohm Stainless steel AISI3003 Plastic reinforced with glass fibre Alu UNI 9002/5 Standard IP54 0°C / +60°C 1,5 m 150 g MC554 BTCS 252/255 - Single phase power supply / 24 VDC The Warner Electric switching power supply units of the BTCS252 series are designed and developed for industrial...

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II - Tension control in open loop MAIN APPLICATIONS - ADVANTAGE Setting type Diameter reading ❐ The most commonly used solution in open loop ❐ No operator intervention admitted ❐ Large roll ø ratio ❐ Physical reading, no reset ❐ Easy to start-up Power supply BTCS252/255 Ultrasonic sensor 90 - 264 VAC

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ULTRASONIC SENSORS BTCS 252/255 - Single phase power supply / 24 VDC Dimensions (mm) The Warner Electric switching power supply units of the BTCS252 series are designed and developed for industrial uses where safety, ease of use and reliability are essential. These units comply with the parameters set out by the Low Voltage Directive. The low working temperature at full power operating temperature combined with the use of first quality components ensure high reliability and duration. Specifications Input 90-264 VAC / 110 VDC, 50/60 Hz HMCS2000-DRV2 □ 1 logic card with 2 individual channels...

Open the catalog to page 11

III - Tension control in open loop MAIN APPLICATIONS - ADVANTAGE Setting type Diameter reading ❐ The most commonly used solution in open loop ❐ Operator intervention admitted ❐ Large roll ø ratio ❐ Physical reading, no reset ❐ Easy to start-up ❐ Graphic display for output percentage value ❐ Functions control available remote/ manually by operator Ultrasonic sensor signal 0 - 10 VDC Power supply BTCS252/255 Ultrasonic sensor 90 - 264 VAC

Open the catalog to page 12

Ultrasonic sensors - Dimensions, see page 11 Ultrasonic Diameter Sensing - HMCS2000-POT-00 □ A simple, analogue, open loop torque control. □ Power supply 24 VDC / Internal consumption 150 mA. □ Adjustable maximum level of the output signal relatively to the ultrasonic input level. □ Graphic display of the output level - full screen equal 10 VDC. □ FAST STOP, HOLD and BRAKE OFF can be activated either through the front switches or through the terminal bloc. □ FAST STOP and HOLD levels are adjustable via potentiometer. □ FAST STOP: a ratio of 1 to 10 times to OPERATING LEVEL □ OPERATING LEVEL:...

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Tension Control Systems

Tension Control Systems

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