Tension Control Systems

Application Examples

Dancer Control
The dancer control system consists of a power supply, dancer control, pivot point sensor, and controlling element, i.e., tension brake or clutch, AC/DC drive-motor or step/servo drive-motor. Dancers provide the web tension while the control and controlling element stabilize dancer operation for unwind, intermediate zone or rewind tension.

AC Motor

Control

Pivot Point Sensor

Load Cell Control

Load cell control system consists of the load cell controller, power supply, load cells and controlling element, i.e., tension brake or clutch, AC/DC drive-motor, step/servo drive-motor. Load cells measure the pull force on the web and compare that force to the set point tension in the control. The control increases or decreases the retarding force. Load cells are used for unwind, intermediate zone or rewind tension control.

Load Cell

Magnum Transducer Power Supply

MCS 2000

Analog Control
The analog system consists of a control module, power supply, and a controlling element, i.e., tension brake or clutch, AC/DC drive-motor, step/servo drive-motor. The analog controller provides output proportional to the input signal for use in unwind, intermediate zone or rewind tensioning.
MTB II

TCS-167 TCS-220

Electronic Control
Electronic control systems are very similar to analog control systems with the exception of using an electronic sensing element such as an ultrasonic or photoelectric sensor. The sensor monitors diameter change in either the unwind or rewind rolls, and provides a corresponding change in output.

Ultrasonic Sensor

DC Motor DC Tach Control

Tension Control Systems

Application Examples

Single Strand Rewind

An AC drive and motor provide rewind control to the windup reel. The drive would incorporate a centerwind tension software to control the rewind torque and speed of the rewind spindle without the need of a dancer or load cell feedback.

Tach Pivot Point Sensor

AC Drive

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DC Motor DC Drive

Unwind/Rewind Combination
AC Motor Unwind or rewind operation is accomplished with a DC motor and drive with a dancer. The dancer tensions the web and provides a driver signal to the DC drive. An input tach sends a primary speed signal and the dancer trims the system to maintain proper tension in either unwind or rewind mode.

Dual Brake Unwind

MTB II

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 TCS-168 or simultaneously. TCS-320

Load Cell

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Magnum Brake

Single Roll Pneumatic Brake Unwind

Pneumatic brake retards the rewind roll, providing the required tension. Tension is set by the loading force applied to the load cells, which send a signal to the controller. The controller signal to the electric/pneumatic transducer controls the air pressure to the brake.

Load Cell

CTLC Transducer

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Pivot Point Sensor TCS-210 Magnetic Particle Brake TCS-167

Single Roll Magnetic Particle Brake Unwind

The magnetic particle brake retards the unwind roll, maintaining tension provided by the dancer rolls weight. The pivot point sensor signals the controller to vary the current to the brake.