Tension Control Systems
80Pages

Tension Control Systems

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...

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 -...

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....

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...

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...

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...

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.

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...

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

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...

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

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...