Tension Controller – Playing An Important Role In The Coiling and Unwinding Industries

In the industries of paper, printing, textile, packaging, metal and wire & cable, in order to maintain high production efficiency, a basic tension controller is essential. It has wide applications, especially in the most related coiling and unwinding industries which need a perfect tension control system to improve production efficiency and product quality.

What Is The Tension Controller?

Tension control refers to the ability to control the tension when the raw materials are transported on the device. In the coiling industry, the tension always needed to be controlled for production requirements, and the tension controller is a type of device for tension control. It has the advantages of small error, fast responding speed, high accuracy and simple adjustment. There’re three types of tension controllers including automatic tension controllers, semi-automatic tension controllers and manual tension controllers.

The basic composition of the tension control system

A typical tension control system is mainly composed of a tension controller, a tension reader, a tension detector, a magnetic powder brake, and a clutch. According to the loop, it can be divided into open loop, closed-loop, or free ring tension control system and it can be divided into types of ultrasonic, floating roll, track arm, according to the monitoring method of different coils.

tension controller

Working principle of the tension controller

The tension controller can directly set the value of the tension control, and then input the signal of the tension sensor as a feedback value. Input the error to the PID or other manipulations for dealing with, and output to the actuator to control.

The tension controller system is controlled between the units of the magnetic powder clutch and must maintain a consistent ratio at the speed, a constant tension among the materials, or controlling tension according to the specified regularity, to ensure high-efficiency productivity and superior product quality.

Why The Tension Controller Is Important In The Coiling and Unwinding Industries

In the production process of paper, textile, plastic film, wire, printing products, tape, metal strip, etc, the roll of the material or wire is crucial to the quality of the product, and constant tension control is required for this purpose, which can make the products withstand the best tension in the process of winding and remain unchanged from the beginning.

The tension controller can be widely used in various applications where tension is precisely measured, with flexible and extensive applicability. The controller compares the deviation of the tension setting value and tension measurement. The output is adjusted through the proportional integration algorithm calculation, so that the web tends to be the setting value, thereby achieving the purpose of constant tension control. Therefore, it is very important to set the appropriate value of proportional integral and stationary zone parameters for the stability of the tension system.

The stability of constant tension control is directly related to the quality of the products. If the tension is too large, the stretch deformation of the processing material will be caused. If the tension is too small, it will deform the stress between the layers of the material and the layers, resulting in the uniform unwinding, affecting the quality of processing.

The Debugging Method Of The Tension Controller

The rewinding & unwinding, or transfer of the tension controller is based on the balance of tension variation in different industries, for high-efficiency production, the debugging method of the tension controller is critical.

The debugging method of the tension controller can be done in the following steps.

1. Programming the related parameters of tension measurement.

2. Make sure the tension controller is installed and the wiring is turned on the power.

3. By manual adjustment, check the system to confirm that the tension is normal and the actuator is operating normally.

4. Ensure the installation of the tension sensor and the wiring is correct. Check whether the signal of the tension sensor is normal.

5. Adjust the PID parameters according to the operation situation for guaranteeing the balance operation of the tension control system.

6. Calibrate the 0 points and the full scale of the tension signal, and ensure the normal display of the tension.

When the tension controller is automatic and the tension is greater than the setting value, the output current value is reduced. When the tension is smaller than the setting value, the output current value increases and the current value is increased with the increased tension in the system, which is greater than the setting value, the output current decreases, and the value of the tension will be reduced, thereby recirculating, achieving automatic control.

Full Automatic Tension Controller

A full automatic tension controller is a high-precision, fully digital, intelligent tension controller, with more advantages and practicality in application and function. It is anti-interference, much more convenient, and stable. It has extremely high tension control accuracy, which is suitable for use in occasions that have high requirements for the accuracy of tension control.

Tension controller

Characteristics of full automatic tension controller

1. High accuracy

The signal can be transmitted via the tension sensor, and then the output signal is processed by the intelligent PID. The actuator can be adjusted to control the changes in the diameter of the tensile scale and the appropriate coil. The output accuracy is as high as 0.1% so that the tension control is more accurate and stable.

2.Single/dual input

Receiving single or dual sensor inputting signal with automatic zeroing and calibration.

3.User-friendly interface

Adopts a full touch screen with simple operation and manual and automatic switching.

interface of tension controller

4.Strong anti-interference

Metal shell with strong anti-interference capacity without sparks.

5.Parameter password protection

Secret code setting will avoid that errors change the setting parameters.

6.Wide applications

Widely used in many industries such as paper-making, printing, packaging, textile, non-woven fabric, etc. The precision of tension control directly affects the processing quality of the product.

Full automatic tension controller manufacturer – Arise

Arise, which is a leading manufacturer, supplier of web guiding system, web guide controller, web guide senor and more other products of web guiding & tension control, in China, with more than 10 years of experience, can provide full automatic tension controller with 32-bit or 16-bit high-precise AD sampling – T500/T1000.

web guiding and tension control products

T500/T1000 web tension controller has high signal precision, quick responding speed and simple operation. The high-performance tension controller will greatly improve production efficiency and quality.


The tension controller provides high-accuracy tension control. In the coiling and unwinding industries, the constant tension control system has played an important role.