Precision Tension Control Solution for Web Materials – TE Series Tension Amplifier + LS Shaft-Mounted Tension Sensor

Hours

Unstable tension during web production frequently causes defects including film stretching, wrinkling, web breakage and register misalignment. Lithium battery, film and printing production lines impose stringent requirements on tension monitoring accuracy. This session features the complete tension monitoring package from Arise: TE full-series tension amplifiers paired with LS400/LS500 shaft-mounted tension sensors. This integrated solution enables real-time collection and precise signal conversion of web tension, delivering stable data support for automatic tension controllers.

Working Principle of the Complete Tension Control System

The LS shaft-mounted tension sensor acts as the front-end acquisition unit. It utilizes high-precision strain gauges to capture the running tension of the web in real time and convert physical tension into weak millivolt electrical signals. Signals are transmitted to the TE series tension amplifier for amplification, filtering and temperature compensation. The amplifier outputs standard 0–10 V / 4–20 mA signals, which connect to T500/T1000 tension controllers or factory PLCs. A complete closed-loop tension control system is established to continuously and stably monitor variations in web tension throughout operation.

LS400/LS500 Shaft-Mounted Tension Sensors (Front-End Acquisition Unit)

1. Core Hardware Specifications

  • Measuring Principle: High-precision full-bridge strain gauges with built-in temperature compensation
  • Accuracy Class: Class 0.1, total comprehensive error ＜1%
  • Protection Rating: LS400 IP45, LS500 IP54
  • Shaft Diameter: Standard 17 mm, compatible with mainstream tension roller shafts
  • Optional Measuring Ranges: 6KG/10KG/15KG/20KG/30KG/50KG/100KG, multiple ranges available
  • Structural Advantages: Built-in overload limiting structure. The sensor core will not be damaged by impact from web joints or instantaneous overload. It features anti-static performance and immunity to electromagnetic interference from inverters, suitable for high-interference workshops such as coating and lithium battery production.

2. Applicable Scenarios

LS400/LS500 shaft-mounted tension sensors are suitable for various winding/unwinding, slitting and coating processes, applicable to web materials including copper & aluminum foil, lithium battery separator, optical film, paper, non-woven fabric and rubber curtain fabric.

  • LS400: For medium & small narrow-width production lines and low-to-medium tension working conditions
  • LS500: For wide-width films, heavy-duty metal webs and high-tension production lines

TE Series Tension Amplifier (Signal Processing Unit)

1. TE100 Economical Tension Amplifier

  • Operation: Simple panel keys for zero adjustment and gain setting;
  • Output: Single-channel 0~10V analog signal;
  • Power Supply: 24VDC, suitable for simple stand-alone production lines and retrofitting of old coating machines;
  • Application: Conventional printing and film production lines with moderate budget and no requirement for data communication.

2. TE200 Networkable Tension Amplifier

  • Equipped with a 2.8-inch color display for real-time tension value display
  • Dual output: 0–10V / 4–20mA
  • Communication: Supports MODBUS RTU 485 and MODBUS TCP Ethernet, compatible with factory MES and PLC systems
  • Standard DIN rail mounting, ideal for automated complete line projects

3. TE300 High-End Touchscreen Tension Amplifier

  • 4.3-inch color touchscreen for intuitive viewing of real-time tension curves
  • High-precision 16-bit AD sampling, sampling speed up to 1μs for zero signal delay
  • Multiple signal input channels, supporting synchronous acquisition from dual sensors
  • Oil-resistant and dust-proof housing, suitable for lithium battery, pharmaceutical clean workshops

Advantages of TE Amplifier + LS Sensor Integrated Package

Fully self-developed hardware & software with matched design, zero signal loss during transmission

The LS sensors and TE amplifiers are tuned collaboratively at the underlying parameter level and calibrated before delivery. No complicated on-site commissioning is required; plug-and-play is available. They support full linkage with Chongqing Enruisi T-series tension controllers and web guiding systems, with mutually compatible communication protocols within the brand.

Specialized optimization for harsh working conditions

Built-in temperature compensation in sensors prevents value drift in high/low-temperature workshops. The amplifier adopts multi-stage filter circuits to isolate electromagnetic interference generated by inverters and ovens, ensuring stable readings during long-term 24-hour continuous production.

Comprehensive range coverage

LS sensors cover a wide measuring range from 6KG for low-tension separators up to 100KG for heavy-duty metal foils. Paired with three models of TE amplifiers, the package fits small lab machines as well as large wide-width complete coating lines.

Full-range localized service network

On-site engineers at domestic offices in Guangdong, Jiangsu, Zhejiang, Shandong and other regions can conduct roller dimension surveys and select sensors with appropriate measuring ranges. Overseas subsidiaries in Vietnam and Indonesia provide synchronized services for exported web processing equipment.

Field Applications in Mainstream Industries

Lithium Battery Manufacturing: Coating and slitting of electrodes and separators. Precise low-tension monitoring prevents separator stretching and electrode wrinkling.

  • Optical Film: Winding of BOPET films and photovoltaic backsheets. Constant tension ensures flat rolls without loose edges.
  • Printing & Flexible Packaging: Color printing, laminating and bag-making processes. Stable tension minimizes register misalignment.
  • Metal Foil Industry: Slitting and winding of copper & aluminum foil. High-tension monitoring avoids foil breakage.
  • Textile & Tire Industry: Production lines for non-woven fabrics and steel cord fabrics. Reliable tension measurement against dust and high-temperature environments.

Simplified Selection Guide

  • Small stand-alone machines, retrofitting of legacy equipment, no communication requirement: LS400 + TE100
  • Automated complete production lines, data upload to PLC/MES required: LS400/LS500 + TE200
  • High-end lithium battery and pharmaceutical production lines, real-time tension curve monitoring required: LS500 + TE300

Next Issue Preview

The next article will focus on fully automatic tension main units: T500/T1000 series tension controllers, and elaborate on the complete machine solution for full closed-loop automatic web tension control.

About Arise

Chongqing ARISE Technology Co., Ltd. With 25 years of focus on web control solutions, we are a Chongqing-level Specialized, Refined, Characteristic and Innovative “Little Giant” Enterprise.

We have obtained ISO9001 Certification and Integration of Informatization and Industrialization Management System Certification. Our products hold EU international certifications including CE, EMC and ESD.

Main products: Vision Inspection System, Coating Quality Tracking System, Web Guiding System, Web Tension Control System, Web Monitoring System, Web Width Measurement & Web Thickness Measurement, a full portfolio of intelligent web processing equipment. Our service network covers more than 150 countries and regions globally.