Advanced Web Process Control: Cleveland - Kidder
Advanced Web Process Control: Cleveland - Kidder
CONTENTS
Clev
elan
d-Ki
dder ®
w w w . C M C c o n t r o l s . c o m w w w . C M C c o n t r o l s . c o m
All CMC Web Tension data sheets and manuals are available on our website. INTRODUCTION.................................................. 1 WHAT TECHNIQUES CAN GET THE MOST FROM MY
LOAD CELLS?...................................................... 20
THE FUNDAMENTALS OF WEB TENSION CONTROL.......... 1 • Orient the Load Cell Properly 20
How to Size and Select • What is Web Tension Control?
• What Requires Web Tension Control?
1
1
• Pay Attention to Roller Weight
• Calculate the Tare Weight and Make it Work For You
21
22
TENSION TRANSDUCERS
(Load Cells) DIN-RAIL AMPLIFIER
DIN-Rail
Amp Digital
Analog
0 - 10 VDC
Output
Dual Beams
Electrical Connector
MOTOR TACH TACH MOTOR
MOTOR DRIVE
Teflon-Coated OR CLUTCH
Temperature Alignment
Compensation Ball Joint
Network
For
Tension
Expansion Pin
Solutions
w w w . C M C c o n t r o l s . c o m
Your Single Source For Web Tension Solutions
ADVANCED WEB PROCESS CONTROL
H A N D B O O K ADVANCED WEB PROCESS CONTROL
CONTENTS
Clev
elan
d-Ki
dder ®
w w w . C M C c o n t r o l s . c o m w w w . C M C c o n t r o l s . c o m
All CMC Web Tension data sheets and manuals are available on our website. INTRODUCTION.................................................. 1 WHAT TECHNIQUES CAN GET THE MOST FROM MY
LOAD CELLS?...................................................... 20
THE FUNDAMENTALS OF WEB TENSION CONTROL.......... 1 • Orient the Load Cell Properly 20
How to Size and Select • What is Web Tension Control?
• What Requires Web Tension Control?
1
1
• Pay Attention to Roller Weight
• Calculate the Tare Weight and Make it Work For You
21
22
INTRODUCTION
INTRODUCTION
Many engineers and technicians are not familiar with the practical application
of load cells (tension transducers) for web tension control. This handbook
describes the steps required to size and select load cells for web process
productivity. Through a logical progression of questions and answers, it provides
fundamental background information, explains decision-making factors, and
offers many useful tips and techniques along the way. Of course, when in
doubt, consult with your supplier before purchasing load cells. They are the
best source of application expertise and can make helpful suggestions to
ensure proper configuration and sizing. The information presented in this
handbook however, will enable you to have informed and meaningful
discussions, resulting in the best chance of success for your application.
FUNDAMENTALS
Q: What is Web Tension Control?
OF WEB TENSION
Web tension control refers to the various methods used to measure
CONTROL
and adjust tension in a moving web. In the context of this handbook,
a web is any material continuously pulled from a roll through some
manufacturing process. Tension is the measurable force that stretches or
HANDBOOK
elongates the web. Web tension control methods range from feeling and
controlling tension by hand to advanced systems that automatically
measure and make adjustments to the process.
1
w w w. C M C c o n t ro l s . c o m
A D V A N C E D W E B P R O C E S S C O N T R O L
THE Q: Why Worry About Web Tension Control? Q: What are Load Cells and Tension Transducers? THE
FUNDAMENTALS FUNDAMENTALS
Properly controlling web tension results in higher quality product The terms "load cell" and "tension transducer" are used inter-
OF WEB TENSION and produces greater throughput. For instance, if the tension is not changeably to describe a sensor that accurately measures the OF WEB TENSION
properly controlled, wrinkles in the material may occur resulting in tension in a moving web. The term "load cell" is commonly used to
CONTROL defective or wasted product. (Refer to Figure 1A) If a roll of material is describe weigh scale sensors that precisely measure the force or load CONTROL
wound without proper tension control, the outer layers may crush the due to the weight of an object. The term has carried over to the web
inner layers leading to starring (Refer to Figure 1B), or the inner layers processing industry since similar sensors measure the force produced by
may telescope out resulting in ruined product (Refer to Figure 1C). tension in the web. The term "transducer" is defined as a device that
When printing on a roll of material, improper tension control results in transforms one type of energy into another. Therefore, a "tension transducer"
smeared ink and fuzzy images from poor registration. Applying too is a sensor that measures the force resulting from tension in a web and
much tension may stretch some materials beyond their elastic limit transforms it into electrical energy.
rendering them unusable. Proper tension control allows the process
to run at high speeds without sacrificing product quality. Both terms will be used throughout this handbook.
HANDBOOK
Basic Method:
Figure 1-B
( Starring ) The operator estimates the web tension by hand and makes
manual adjustments to the process. This approach requires
100% operator intervention.
The operator taps on the web and by "feel" tries to determine the
amount of tension. Appropriate corrective action is taken to change the
tension by manually changing brake torques, dancer loads, gear ratios,
or motor speeds. The operator continues tapping the web and making
adjustments until a satisfactory result is achieved. Because this is a
manual process, adjustments take time, and as a result, much wasted
product is produced.
Figure 1-C
( Telescoping )
2 3
w w w. C M C c o n t ro l s . c o m
A D V A N C E D W E B P R O C E S S C O N T R O L
THE Q: Why Worry About Web Tension Control? Q: What are Load Cells and Tension Transducers? THE
FUNDAMENTALS FUNDAMENTALS
Properly controlling web tension results in higher quality product The terms "load cell" and "tension transducer" are used inter-
OF WEB TENSION and produces greater throughput. For instance, if the tension is not changeably to describe a sensor that accurately measures the OF WEB TENSION
properly controlled, wrinkles in the material may occur resulting in tension in a moving web. The term "load cell" is commonly used to
CONTROL defective or wasted product. (Refer to Figure 1A) If a roll of material is describe weigh scale sensors that precisely measure the force or load CONTROL
wound without proper tension control, the outer layers may crush the due to the weight of an object. The term has carried over to the web
inner layers leading to starring (Refer to Figure 1B), or the inner layers processing industry since similar sensors measure the force produced by
may telescope out resulting in ruined product (Refer to Figure 1C). tension in the web. The term "transducer" is defined as a device that
When printing on a roll of material, improper tension control results in transforms one type of energy into another. Therefore, a "tension transducer"
smeared ink and fuzzy images from poor registration. Applying too is a sensor that measures the force resulting from tension in a web and
much tension may stretch some materials beyond their elastic limit transforms it into electrical energy.
rendering them unusable. Proper tension control allows the process
to run at high speeds without sacrificing product quality. Both terms will be used throughout this handbook.
HANDBOOK
Basic Method:
Figure 1-B
( Starring ) The operator estimates the web tension by hand and makes
manual adjustments to the process. This approach requires
100% operator intervention.
The operator taps on the web and by "feel" tries to determine the
amount of tension. Appropriate corrective action is taken to change the
tension by manually changing brake torques, dancer loads, gear ratios,
or motor speeds. The operator continues tapping the web and making
adjustments until a satisfactory result is achieved. Because this is a
manual process, adjustments take time, and as a result, much wasted
product is produced.
Figure 1-C
( Telescoping )
2 3
w w w. C M C c o n t ro l s . c o m
A D V A N C E D W E B P R O C E S S C O N T R O L
THE With this basic method, there is no consistent way of measuring or Best Method: THE
altering the tension. Attempts may be made to record the settings of the
FUNDAMENTALS FUNDAMENTALS
motor speeds, brake pressure, or dancer loads, but as brake pads and Load cells are used along with controllers and actuators to
OF WEB TENSION other machine parts wear, the settings will produce different tension automatically measure and adjust web tension. This approach OF WEB TENSION
levels. Temperature changes and inconsistencies in the material will also requires minimum operator intervention. (Refer to Figure 2)
CONTROL affect tension. Furthermore, different operators have differing opinions CONTROL
on which tension feels right. Product quality is suspect and inconsistent.
TENSION TRANSDUCERS
(Load Cells) DIN-RAIL AMPLIFIER
DIN-Rail
Most importantly, this method is an unsafe and unacceptable Amp Digital
Analog
Better Method:
MOTOR TACH TACH MOTOR
Load cells are used to measure tension and the value is displayed
on an indicator. The operator still manually adjusts the tension.
This requires a great deal of operator intervention. MOTOR DRIVE
OR CLUTCH
Load cells are added to the rollers (or sheaves and pulleys) in the tension
zones. The load cells measure the tension and the values are displayed
on tension indicators (meters, or screen displays). The operator takes the
appropriate corrective action to adjust the tension by manually changing MOTOR
CONTROL
MOTOR
CONTROL
UNWIND DRIVE REWIND
brake torques, dancer loads, gear ratios, or motor speeds. The operator TENSION
CONTROLLER
TENSION
CONTROLLER
TENSION
CONTROLLER
continues to read the tension values and makes the necessary adjustments
until proper tension is achieved. Manual adjustments are still required, Figure 2
but the tension values are accurate and can now be documented. This ( Complete Web Tension Converting System )
allows for the line tension to be duplicated on the next run or when
run by a different operator. There is a consistent method of measuring Load cells are added to the rollers (or sheaves and pulleys) in the tension
and displaying tension but no consistent method of controlling it. zones. The load cells are connected to a device that displays the tension
HANDBOOK
Tension control still relies on operator intervention, which takes time to value and automatically controls the brakes, dancers, gear ratios, or
correct. As a result, much wasted product is still produced. Product motors. The operator enters the desired tension setting (tension set point)
quality is greatly improved but is somewhat inconsistent. and the appropriate corrective action is done automatically by changing
brake torques, dancer loads, gear ratios, or motor speeds. The controller
Since the tension is known, so too are the limits to which the line speed may be a standalone device, PLC, or programmable drive. All perform
may be increased before the material stretches or web breaks. The line closed-loop tension control. They continually compare the tension set
speed may be increased but only to the amount that it can be controlled. point to the actual tension being measured by the load cells and auto-
matically take corrective action to ensure that these values agree.
Manual intervention by the operator still limits the response
time and how tightly the tension values can be controlled. This method provides a consistent means of measuring and
Though greatly improved, throughput is not yet maximized. controlling tension. Tension control is done automatically and
requires minimum operator intervention. Product quality is
at its best and is consistent. Corrective action takes place
immediately. As a result, little wasted product is produced.
4 5
w w w. C M C c o n t ro l s . c o m
A D V A N C E D W E B P R O C E S S C O N T R O L
THE With this basic method, there is no consistent way of measuring or Best Method: THE
altering the tension. Attempts may be made to record the settings of the
FUNDAMENTALS FUNDAMENTALS
motor speeds, brake pressure, or dancer loads, but as brake pads and Load cells are used along with controllers and actuators to
OF WEB TENSION other machine parts wear, the settings will produce different tension automatically measure and adjust web tension. This approach OF WEB TENSION
levels. Temperature changes and inconsistencies in the material will also requires minimum operator intervention. (Refer to Figure 2)
CONTROL affect tension. Furthermore, different operators have differing opinions CONTROL
on which tension feels right. Product quality is suspect and inconsistent.
TENSION TRANSDUCERS
(Load Cells) DIN-RAIL AMPLIFIER
DIN-Rail
Most importantly, this method is an unsafe and unacceptable Amp Digital
Analog
Better Method:
MOTOR TACH TACH MOTOR
Load cells are used to measure tension and the value is displayed
on an indicator. The operator still manually adjusts the tension.
This requires a great deal of operator intervention. MOTOR DRIVE
OR CLUTCH
Load cells are added to the rollers (or sheaves and pulleys) in the tension
zones. The load cells measure the tension and the values are displayed
on tension indicators (meters, or screen displays). The operator takes the
appropriate corrective action to adjust the tension by manually changing MOTOR
CONTROL
MOTOR
CONTROL
UNWIND DRIVE REWIND
brake torques, dancer loads, gear ratios, or motor speeds. The operator TENSION
CONTROLLER
TENSION
CONTROLLER
TENSION
CONTROLLER
continues to read the tension values and makes the necessary adjustments
until proper tension is achieved. Manual adjustments are still required, Figure 2
but the tension values are accurate and can now be documented. This ( Complete Web Tension Converting System )
allows for the line tension to be duplicated on the next run or when
run by a different operator. There is a consistent method of measuring Load cells are added to the rollers (or sheaves and pulleys) in the tension
and displaying tension but no consistent method of controlling it. zones. The load cells are connected to a device that displays the tension
HANDBOOK
Tension control still relies on operator intervention, which takes time to value and automatically controls the brakes, dancers, gear ratios, or
correct. As a result, much wasted product is still produced. Product motors. The operator enters the desired tension setting (tension set point)
quality is greatly improved but is somewhat inconsistent. and the appropriate corrective action is done automatically by changing
brake torques, dancer loads, gear ratios, or motor speeds. The controller
Since the tension is known, so too are the limits to which the line speed may be a standalone device, PLC, or programmable drive. All perform
may be increased before the material stretches or web breaks. The line closed-loop tension control. They continually compare the tension set
speed may be increased but only to the amount that it can be controlled. point to the actual tension being measured by the load cells and auto-
matically take corrective action to ensure that these values agree.
Manual intervention by the operator still limits the response
time and how tightly the tension values can be controlled. This method provides a consistent means of measuring and
Though greatly improved, throughput is not yet maximized. controlling tension. Tension control is done automatically and
requires minimum operator intervention. Product quality is
at its best and is consistent. Corrective action takes place
immediately. As a result, little wasted product is produced.
4 5
w w w. C M C c o n t ro l s . c o m
A D V A N C E D W E B P R O C E S S C O N T R O L
THE Since the tension is known, so too are the limits to which the line speed THE
may be increased before the material stretches or web breaks. The line
FUNDAMENTALS FUNDAMENTALS
speed may be increased to the amount that it can be controlled. Highly
OF WEB TENSION responsive automatic closed-loop tension devices tightly control tension OF WEB TENSION
values. Throughput is maximized. Limiting factors are only the response
CONTROL time of the control loop and actual process limitations. CONTROL
The transducer is first fastened to the machine frame at one end and
to a roller on the other end. Then, the web is wrapped over the roller.
(Refer to Figure 3) Inside each transducer, strain gages have been
Figure 4
attached to a pair of beams made of spring steel. (Refer to Figure 4) ( Web Tension Sensing Transducer )
Referred to as dual beams, they are fixed at one end with the free end
See full-color version on inside cover foldout
connecting to the roller. As tension is applied to the web, the force is
transferred from the roller directly to the transducer.
HANDBOOK
Figure 3
( Web Tension Indicating System )
A D V A N C E D W E B P R O C E S S C O N T R O L
THE Since the tension is known, so too are the limits to which the line speed THE
may be increased before the material stretches or web breaks. The line
FUNDAMENTALS FUNDAMENTALS
speed may be increased to the amount that it can be controlled. Highly
OF WEB TENSION responsive automatic closed-loop tension devices tightly control tension OF WEB TENSION
values. Throughput is maximized. Limiting factors are only the response
CONTROL time of the control loop and actual process limitations. CONTROL
The transducer is first fastened to the machine frame at one end and
to a roller on the other end. Then, the web is wrapped over the roller.
(Refer to Figure 3) Inside each transducer, strain gages have been
Figure 4
attached to a pair of beams made of spring steel. (Refer to Figure 4) ( Web Tension Sensing Transducer )
Referred to as dual beams, they are fixed at one end with the free end
See full-color version on inside cover foldout
connecting to the roller. As tension is applied to the web, the force is
transferred from the roller directly to the transducer.
HANDBOOK
Figure 3
( Web Tension Indicating System )
A D V A N C E D W E B P R O C E S S C O N T R O L
THE To accommodate a larger force, the cross sectional area of the beam
FUNDAMENTALS
can be increased by making it either wider or thicker. The greater the Cleveland-Kidder® Transducer Styles
transducer load rating (Maximum Working Force or MWF), the larger
Rotating Shafts
There are load cell designs for use with stationary (fixed or dead) shaft • Available in a variety of • Completely sealed;
APPLICATION load ratings (25 lb. to Corrosion and chemical
rollers and for rotating (live) shaft rollers. (Refer to Figure 7) There are 30,000 lb.) and sizes resisting (Stainless Steel
load cells that are designed for use with commercially available pillow (6.5 to 17 inches long). 410 or Anodized
block bearings. Space limitations may be a factor so slim and low profile • Resists liquids and wet Aluminum Alloy 6061).
environments. • Provides 500% overload
designs may be required. The environment may be wet or contain • Alternative to UPB–Low
• For use with pillow • Compact low profile design protection.
harsh chemicals, in which case a sealed and corrosive resistant load cell fits into tight places. • Removable mounting friction bearing design ideal
block bearings. for low tension requirements.
is the best solution. (Refer to Figure 6) Finally, different styles of load • CE compliant. plate for easy installation
cells have different tension ranges. of pillow block bearing. • See additional information
shown for Type SS above.
Many application specific questions need to be asked and answered Cantilevered Cantilevered
before choosing a load cell. The following steps contain these important Transducer CLT Tensi-Master®
questions. • Wide range of maximum CR Transducer • Negligible displacement
load ratings – from 0.1 lb. of “twin beam” design,
to 500 lbs. resulting in high level linear
Applications
Narrow Web
(continued page 10) • Reduces maintenance costs. output signal, high frequency
response and overall system
• For use with cantilevered • Provides flexibility of
stability.
rollers or pulleys. specifying almost any fixed
• Wide range of maximum • Easily oriented at any angle,
• Accommodates almost any shaft roller.
load ratings – from 5 lb. to accommodating all web
customer roller, eliminating • Eliminates need for custom 150 lb. load ratings.
designed transducers for paths.
need & expense of • Accommodates customer- • CE compliant.
integrated roller. non-standard applications.
mounted pulley.
• CE compliant. • Cylindrical body design and
CMC mounting kits enables
it to be oriented to any
web path.
Figure 7
SELECTING
( CMC Transducer Selection Guide )
THE STYLE OF
Figure 6
( Environmentally Sealed Load Cells ) LOAD CELL
FOR YOUR
APPLICATION
8 9
w w w. C M C c o n t ro l s . c o m
A D V A N C E D W E B P R O C E S S C O N T R O L
THE To accommodate a larger force, the cross sectional area of the beam
FUNDAMENTALS
can be increased by making it either wider or thicker. The greater the Cleveland-Kidder® Transducer Styles
transducer load rating (Maximum Working Force or MWF), the larger
Rotating Shafts
There are load cell designs for use with stationary (fixed or dead) shaft • Available in a variety of • Completely sealed;
APPLICATION load ratings (25 lb. to Corrosion and chemical
rollers and for rotating (live) shaft rollers. (Refer to Figure 7) There are 30,000 lb.) and sizes resisting (Stainless Steel
load cells that are designed for use with commercially available pillow (6.5 to 17 inches long). 410 or Anodized
block bearings. Space limitations may be a factor so slim and low profile • Resists liquids and wet Aluminum Alloy 6061).
environments. • Provides 500% overload
designs may be required. The environment may be wet or contain • Alternative to UPB–Low
• For use with pillow • Compact low profile design protection.
harsh chemicals, in which case a sealed and corrosive resistant load cell fits into tight places. • Removable mounting friction bearing design ideal
block bearings. for low tension requirements.
is the best solution. (Refer to Figure 6) Finally, different styles of load • CE compliant. plate for easy installation
cells have different tension ranges. of pillow block bearing. • See additional information
shown for Type SS above.
Many application specific questions need to be asked and answered Cantilevered Cantilevered
before choosing a load cell. The following steps contain these important Transducer CLT Tensi-Master®
questions. • Wide range of maximum CR Transducer • Negligible displacement
load ratings – from 0.1 lb. of “twin beam” design,
to 500 lbs. resulting in high level linear
Applications
Narrow Web
(continued page 10) • Reduces maintenance costs. output signal, high frequency
response and overall system
• For use with cantilevered • Provides flexibility of
stability.
rollers or pulleys. specifying almost any fixed
• Wide range of maximum • Easily oriented at any angle,
• Accommodates almost any shaft roller.
load ratings – from 5 lb. to accommodating all web
customer roller, eliminating • Eliminates need for custom 150 lb. load ratings.
designed transducers for paths.
need & expense of • Accommodates customer- • CE compliant.
integrated roller. non-standard applications.
mounted pulley.
• CE compliant. • Cylindrical body design and
CMC mounting kits enables
it to be oriented to any
web path.
Figure 7
SELECTING
( CMC Transducer Selection Guide )
THE STYLE OF
Figure 6
( Environmentally Sealed Load Cells ) LOAD CELL
FOR YOUR
APPLICATION
8 9
w w w. C M C c o n t ro l s . c o m
A D V A N C E D W E B P R O C E S S C O N T R O L
SELECTING Step 1 - Determine if you have a wide web, narrow web, or Step 2 - Determine if you have a stationary shaft or rotating SELECTING
LOAD CELL Wide Web: Typically a wide web is over 20 inches wide and utilizes a Stationary Shaft Rollers: Rollers are either stationary shaft or rotating LOAD CELL
roller assembly supported on both ends. Some production processes shaft. Stationary shaft rollers have a shaft that run all the way through
FOR YOUR utilizing a wide web include paper, film, foil, and plastics; printing and the assembly. The outer shell or sleeve is a cylinder that rotates around FOR YOUR
the converting of these products such as coating, slitting, and laminating. the shaft on bearings. The shaft does not rotate but remains stationary.
APPLICATION APPLICATION
Stationary shaft rollers are also referred to as fixed or dead shaft rollers.
CMC’s standard product offerings for wide webs are the Cartridge (Refer to Figure 10)
Style Transducers, Slim Cell Transducer, and UPB Washdown Duty LC.
(Refer to Figure 7)
HANDBOOK
very narrow width products that run over a pulley the tension measurement.
or guide roller. (Refer to Figure 9)
The Cartridge Style Transducer and Slim Cell Transducers are designed
CMC's standard product offerings for narrow webs for wide web rollers with stationary shafts. The Cartridge Style Transducer
are the CLT and CR Style Transducers (Refer to is very versatile since it offers a variety of mounting options—flange
Figure 7). Other styles are available that have been mount and pillow mounting kits. The Slim Cell Transducer is a low profile
designed for specific applications. design and can be mounted inside or outside the machine frame. It is
corrosive, chemical, and water resisting and is designed to handle high
Only one transducer is required per roller overloads.
since it supports a cantilevered roller or pulley.
Rotating Shaft Rollers: Rotating shaft rollers are designed so that the
shaft is part of the rotating assembly. The outer shell or sleeve is integral
to the shaft, there are no bearings in the assembly, and the shaft
Figure 9
( Pulley ) rotates. (Refer to Figure 11)
10 11
w w w. C M C c o n t ro l s . c o m
A D V A N C E D W E B P R O C E S S C O N T R O L
SELECTING Step 1 - Determine if you have a wide web, narrow web, or Step 2 - Determine if you have a stationary shaft or rotating SELECTING
LOAD CELL Wide Web: Typically a wide web is over 20 inches wide and utilizes a Stationary Shaft Rollers: Rollers are either stationary shaft or rotating LOAD CELL
roller assembly supported on both ends. Some production processes shaft. Stationary shaft rollers have a shaft that run all the way through
FOR YOUR utilizing a wide web include paper, film, foil, and plastics; printing and the assembly. The outer shell or sleeve is a cylinder that rotates around FOR YOUR
the converting of these products such as coating, slitting, and laminating. the shaft on bearings. The shaft does not rotate but remains stationary.
APPLICATION APPLICATION
Stationary shaft rollers are also referred to as fixed or dead shaft rollers.
CMC’s standard product offerings for wide webs are the Cartridge (Refer to Figure 10)
Style Transducers, Slim Cell Transducer, and UPB Washdown Duty LC.
(Refer to Figure 7)
HANDBOOK
very narrow width products that run over a pulley the tension measurement.
or guide roller. (Refer to Figure 9)
The Cartridge Style Transducer and Slim Cell Transducers are designed
CMC's standard product offerings for narrow webs for wide web rollers with stationary shafts. The Cartridge Style Transducer
are the CLT and CR Style Transducers (Refer to is very versatile since it offers a variety of mounting options—flange
Figure 7). Other styles are available that have been mount and pillow mounting kits. The Slim Cell Transducer is a low profile
designed for specific applications. design and can be mounted inside or outside the machine frame. It is
corrosive, chemical, and water resisting and is designed to handle high
Only one transducer is required per roller overloads.
since it supports a cantilevered roller or pulley.
Rotating Shaft Rollers: Rotating shaft rollers are designed so that the
shaft is part of the rotating assembly. The outer shell or sleeve is integral
to the shaft, there are no bearings in the assembly, and the shaft
Figure 9
( Pulley ) rotates. (Refer to Figure 11)
10 11
w w w. C M C c o n t ro l s . c o m
A D V A N C E D W E B P R O C E S S C O N T R O L
SELECTING To estimate the load requirement for narrow web transducers, SELECTING
double the running tension value. Ensure that the transducer you
THE STYLE OF THE STYLE OF
are considering is designed for this load.
LOAD CELL LOAD CELL
Later in this handbook, a transducer sizing calculation will be
FOR YOUR completed to determine which load rating to actually select. FOR YOUR
For now, use this guideline then check later against the actual calculation.
APPLICATION APPLICATION
Note: 1 pt = 0.001”
0.0005” 0.25 8 pt. 3.0
Stationary Versus Rotating Shaft Rollers: Many times the application 0.001” 0.05 12 pt. 4.0
dictates the type of roller required. For very high speed (rpm) require- 0.002” 1.0 15 pt. 5.0
Cellophane 20 pt. 7.0
ments, rotating shaft rollers are generally utilized since they exhibit higher 0.00075” 0.5 25 pt. 9.0
resonant frequencies than stationary shaft rollers. Large diameter roller 0.001” 0.75 30 pt. 11.0
construction (with typically large loads) favors rotating shaft rollers that 0.002” 1.0 35 pt. 13.0
are used with under pillow block bearings. Stationary shaft rollers are Nylon & Cast Propylene (non-Oriented) 45 pt. 15.0
used in many applications since they are relatively easy to manufacture 0.00075” 0.15 65 pt. 19.0
0.001” 0.25 Laminations
and are readily available. 0.002” 0.5 25 lb. Paper/.0005” PE/.00035” Foil /.001” PE 3.0
Paper .001” Cello /.0005” PE /.001” Cello 1.5
Step 3 - Determine the proper tension 15 lbs./ream (3,000 sq. ft.) 0.5
20 lbs./ream 0.75
Many times the process or production engineers have a good idea of 30 lbs./ream 1.0 NOTE: When these substrates are coated with polyethylene,
40 lbs./ream 1.5 nylon, polypropylene, EVA, EAA and EEA ... add the following
what the running tensions should be. If these are not known, approximate 60 lbs./ream 2.0 tension values to the values listed above for the substrate only.
the tension based on the thickness and type of material. Figure 12 can 80 lbs./ream 2.5
be used for approximating tensions. Tensions are given in PLI, which 120 lbs./ream 3.5 Approximate Tension
Coating Thickness
stands for Pounds per Lineal Inch. To determine the tension in the material, 160 lbs./ream 4.5 (lbs. /inch)
multiply the PLI by the width of the web. For example, 4 mil thickness 200 lbs./ream 5.5
0.0005” to 0.001 0.12
240 lbs./ream 6.5
of nylon or cast propylene (non-oriented) requires approximately 1 PLI 280 lbs./ream 7.5
0.0011” to 0.002 0.25
of tension (0.25 lb. /in /mil x 4 mil = 1 lb./in). To run a 60 inch wide
Copper Wire
web of Propylene a typical tension of 60 lb. is required (1 lb./in x 60
in = 60 lb.). AWG Tension AWG Tension
8 30.0 lb. 20 5.0 lb.
To estimate the load requirement for wide web transducers, use the 10 20.0 lb. 24 4.5 lb.
12 12.0 lb. 30 1.25 lb.
running tension value. Ensure that the transducer you are considering 14 9.0 lb. 36 0.25 lb.
is designed for this load. 16 6.0 lb. 40 0.1 lb.
12 Figure 12 13
w w w. C M C c o n t ro l s . c o m
A D V A N C E D W E B P R O C E S S C O N T R O L
SELECTING To estimate the load requirement for narrow web transducers, SELECTING
double the running tension value. Ensure that the transducer you
THE STYLE OF THE STYLE OF
are considering is designed for this load.
LOAD CELL LOAD CELL
Later in this handbook, a transducer sizing calculation will be
FOR YOUR completed to determine which load rating to actually select. FOR YOUR
For now, use this guideline then check later against the actual calculation.
APPLICATION APPLICATION
Note: 1 pt = 0.001”
0.0005” 0.25 8 pt. 3.0
Stationary Versus Rotating Shaft Rollers: Many times the application 0.001” 0.05 12 pt. 4.0
dictates the type of roller required. For very high speed (rpm) require- 0.002” 1.0 15 pt. 5.0
Cellophane 20 pt. 7.0
ments, rotating shaft rollers are generally utilized since they exhibit higher 0.00075” 0.5 25 pt. 9.0
resonant frequencies than stationary shaft rollers. Large diameter roller 0.001” 0.75 30 pt. 11.0
construction (with typically large loads) favors rotating shaft rollers that 0.002” 1.0 35 pt. 13.0
are used with under pillow block bearings. Stationary shaft rollers are Nylon & Cast Propylene (non-Oriented) 45 pt. 15.0
used in many applications since they are relatively easy to manufacture 0.00075” 0.15 65 pt. 19.0
0.001” 0.25 Laminations
and are readily available. 0.002” 0.5 25 lb. Paper/.0005” PE/.00035” Foil /.001” PE 3.0
Paper .001” Cello /.0005” PE /.001” Cello 1.5
Step 3 - Determine the proper tension 15 lbs./ream (3,000 sq. ft.) 0.5
20 lbs./ream 0.75
Many times the process or production engineers have a good idea of 30 lbs./ream 1.0 NOTE: When these substrates are coated with polyethylene,
40 lbs./ream 1.5 nylon, polypropylene, EVA, EAA and EEA ... add the following
what the running tensions should be. If these are not known, approximate 60 lbs./ream 2.0 tension values to the values listed above for the substrate only.
the tension based on the thickness and type of material. Figure 12 can 80 lbs./ream 2.5
be used for approximating tensions. Tensions are given in PLI, which 120 lbs./ream 3.5 Approximate Tension
Coating Thickness
stands for Pounds per Lineal Inch. To determine the tension in the material, 160 lbs./ream 4.5 (lbs. /inch)
multiply the PLI by the width of the web. For example, 4 mil thickness 200 lbs./ream 5.5
0.0005” to 0.001 0.12
240 lbs./ream 6.5
of nylon or cast propylene (non-oriented) requires approximately 1 PLI 280 lbs./ream 7.5
0.0011” to 0.002 0.25
of tension (0.25 lb. /in /mil x 4 mil = 1 lb./in). To run a 60 inch wide
Copper Wire
web of Propylene a typical tension of 60 lb. is required (1 lb./in x 60
in = 60 lb.). AWG Tension AWG Tension
8 30.0 lb. 20 5.0 lb.
To estimate the load requirement for wide web transducers, use the 10 20.0 lb. 24 4.5 lb.
12 12.0 lb. 30 1.25 lb.
running tension value. Ensure that the transducer you are considering 14 9.0 lb. 36 0.25 lb.
is designed for this load. 16 6.0 lb. 40 0.1 lb.
12 Figure 12 13
w w w. C M C c o n t ro l s . c o m
A D V A N C E D W E B P R O C E S S C O N T R O L
Check the roller shaft diameters that the load cell can accommodate. A
split bushing, which the manufacturer can supply, may be required to
accommodate smaller shaft diameters. You may need to turn down the
Type S
ends of the roller shaft if it is larger than the load cell can accept.
Stud Mounting
HANDBOOK
any other available information. (Refer to Figure 22 for a detailed Type BR
selection guide for CMC load cells) Bearing Replacement Mounting
Make sure to consult with your supplier. They will be able to recommend
the best style load cell for your application and will give you tips on how
to get the most out of it. They’ll recommend how it should be mounted
and oriented to get the best performance. This will be useful in determining
the parameters required to size the load cell to the proper load rating,
which is the next step.
Type PB
Pillow Block Mounting
Figure 13
( Cartridge Style Transducer Mounting Configurations )
14 15
w w w. C M C c o n t ro l s . c o m
A D V A N C E D W E B P R O C E S S C O N T R O L
Check the roller shaft diameters that the load cell can accommodate. A
split bushing, which the manufacturer can supply, may be required to
accommodate smaller shaft diameters. You may need to turn down the
Type S
ends of the roller shaft if it is larger than the load cell can accept.
Stud Mounting
HANDBOOK
any other available information. (Refer to Figure 22 for a detailed Type BR
selection guide for CMC load cells) Bearing Replacement Mounting
Make sure to consult with your supplier. They will be able to recommend
the best style load cell for your application and will give you tips on how
to get the most out of it. They’ll recommend how it should be mounted
and oriented to get the best performance. This will be useful in determining
the parameters required to size the load cell to the proper load rating,
which is the next step.
Type PB
Pillow Block Mounting
Figure 13
( Cartridge Style Transducer Mounting Configurations )
14 15
w w w. C M C c o n t ro l s . c o m
A D V A N C E D W E B P R O C E S S C O N T R O L
SIZING THE SIZING THE TRANSDUCER FOR Q: What Formulas Are Used For Proper Sizing? SIZING THE
Load cells (tension transducers) are electromechanical devices that have as well as the actual tension in the material. The key is to get the values
inherent design limitations. This restricts the tension (force) range over for the minimum and maximum tension, the weight of the roller, and a
which they can operate. If the force is too high, the electromechanical sketch of the web path. From there, a supplier can determine the wrap
elements will be overstressed and fail. If the force is too low, the signal angle, other appropriate angles, and perform the calculations.
output is too low to measure. Because of these restrictions, each style of
load cell is offered with a choice of force ratings—referred to as the Values for each parameter are inserted into the formula to determine
Maximum Working Force (MWF) rating. the Maximum Working Force (MWF) required for the application. Select
a transducer whose load rating (MWF) meets or exceeds the calculated
The goal is to select an MWF rating that will meet the tension range MWF.
requirement without overstressing the electromechanical elements. This
is referred to as sizing the transducer.
CANTILEVERED (CLT) SIZING CALCULATION
Tension Range is the ratio of the maximum MWF = Maximum Working Force (lbs.)
T = Maximum Total Tension (lbs.)
running tension divided by the minimum running tension. K = Transient Tension Overload Factor
(normally between 1.4 and 2)
Example: What is the tension range with a max A = Wrap Angle (degrees)
running tension of 80 lbs and a min of 10 lbs? B = Angle of Tension Force (degrees)
W = Weight of Cantilevered Roller
Answer: 80/10 = 8:1 * The MWF calculation defines the force on each individual load cell.
** If Angle B is below horizontal use + in calculation. If Angle B is above
horizontal use – in calculation.
If the required tension range is small, 8:1 or less, this becomes less critical
UPB SIZING CALCULATION
so the transducer can be sized for a larger load and still produce a SIZE L (in.) D (in.)
significant signal at the low-tension requirement. If the required tension 2KT sin A– [HsinB + LcosB] +_ W[LcosC - HsinC] **
[ ] UPB1 2.5 0.98
range is large, 20:1 or 30:1, the MWF rating must be as small as possible. 2
MWF*= –––––––––––––––––––––––––––––––––––––––––––––– UPB2 4.5 1.25
The load cell’s rating must closely match the maximum tension require- 2L UPB3 6.5 2.10
ment to have enough range left to provide a significant measurement MWF = Maximum Working Force (lbs.)
at the low end. The range over which load cells can operate depends (used to select the proper force rating
upon its design and how it is applied. of the transducer)
K = Transient Tension Overload Factor
The formulas for calculating MWF are derived from the design of the (normally 1.4 for most applications)
transducers themselves. These formulas are referred to as sizing formulas. T = Maximum Total Tension (lbs.)
A = Wrap Angle (degrees)
Inserting values for various parameters in the formulas produce the
B = Angle of Tension Force (degrees)
MWF required by a specific application. Make sure your supplier reviews W = Weight of Roller
these calculations. C = Mounting Angle (degrees)
H = Bearing Height + D
* The MWF calculation defines the force on each individual load cell.
** If Angle B is below horizontal use + in calculation. If Angle B is above
horizontal use – in calculation.
Figure 14
16 17
w w w. C M C c o n t ro l s . c o m
A D V A N C E D W E B P R O C E S S C O N T R O L
SIZING THE SIZING THE TRANSDUCER FOR Q: What Formulas Are Used For Proper Sizing? SIZING THE
Load cells (tension transducers) are electromechanical devices that have as well as the actual tension in the material. The key is to get the values
inherent design limitations. This restricts the tension (force) range over for the minimum and maximum tension, the weight of the roller, and a
which they can operate. If the force is too high, the electromechanical sketch of the web path. From there, a supplier can determine the wrap
elements will be overstressed and fail. If the force is too low, the signal angle, other appropriate angles, and perform the calculations.
output is too low to measure. Because of these restrictions, each style of
load cell is offered with a choice of force ratings—referred to as the Values for each parameter are inserted into the formula to determine
Maximum Working Force (MWF) rating. the Maximum Working Force (MWF) required for the application. Select
a transducer whose load rating (MWF) meets or exceeds the calculated
The goal is to select an MWF rating that will meet the tension range MWF.
requirement without overstressing the electromechanical elements. This
is referred to as sizing the transducer.
CANTILEVERED (CLT) SIZING CALCULATION
Tension Range is the ratio of the maximum MWF = Maximum Working Force (lbs.)
T = Maximum Total Tension (lbs.)
running tension divided by the minimum running tension. K = Transient Tension Overload Factor
(normally between 1.4 and 2)
Example: What is the tension range with a max A = Wrap Angle (degrees)
running tension of 80 lbs and a min of 10 lbs? B = Angle of Tension Force (degrees)
W = Weight of Cantilevered Roller
Answer: 80/10 = 8:1 * The MWF calculation defines the force on each individual load cell.
** If Angle B is below horizontal use + in calculation. If Angle B is above
horizontal use – in calculation.
If the required tension range is small, 8:1 or less, this becomes less critical
UPB SIZING CALCULATION
so the transducer can be sized for a larger load and still produce a SIZE L (in.) D (in.)
significant signal at the low-tension requirement. If the required tension 2KT sin A– [HsinB + LcosB] +_ W[LcosC - HsinC] **
[ ] UPB1 2.5 0.98
range is large, 20:1 or 30:1, the MWF rating must be as small as possible. 2
MWF*= –––––––––––––––––––––––––––––––––––––––––––––– UPB2 4.5 1.25
The load cell’s rating must closely match the maximum tension require- 2L UPB3 6.5 2.10
ment to have enough range left to provide a significant measurement MWF = Maximum Working Force (lbs.)
at the low end. The range over which load cells can operate depends (used to select the proper force rating
upon its design and how it is applied. of the transducer)
K = Transient Tension Overload Factor
The formulas for calculating MWF are derived from the design of the (normally 1.4 for most applications)
transducers themselves. These formulas are referred to as sizing formulas. T = Maximum Total Tension (lbs.)
A = Wrap Angle (degrees)
Inserting values for various parameters in the formulas produce the
B = Angle of Tension Force (degrees)
MWF required by a specific application. Make sure your supplier reviews W = Weight of Roller
these calculations. C = Mounting Angle (degrees)
H = Bearing Height + D
* The MWF calculation defines the force on each individual load cell.
** If Angle B is below horizontal use + in calculation. If Angle B is above
horizontal use – in calculation.
Figure 14
16 17
w w w. C M C c o n t ro l s . c o m
A D V A N C E D W E B P R O C E S S C O N T R O L
SLIM CELL SIZING CALCULATION HOW TO SELECT THE Determine the Maximum Tension T, and the
MWF* = T x K x sin (A/2) +_ (W/2) x sin (B)** RIGHT TRANSDUCERS minimum tension that is required for your process.
If this is not known, consult your transducer supplier.
MWF = Maximum Working Force (lbs.) For RR Donnelley & Sons, two CMC SC The supplier should have charts that indicate typical
T = Maximum Total Tension (lbs.) Transducers are used on each tension roller, one tensions for various materials.
K = Transient Tension Overload Factor on each side. The web is wrapped around the Weigh the roller or calculate the roller weight
(normally 1.5 for most applications) tension roller. The Transducers measure the force to determine W. K is a safety factor that is used
A = Wrap Angle (degrees) that is exerted on the roller by the tension in the to account for tension transient overloads (a
B = Angle of Tension Force (degrees) moving web. The maximum working force (MWF) value of 1.4 to 2.0 is typical, depending on the
W = Weight of Roller exerted on the transducers is then calculated application.).
from the following equation. Insert those values into the equation to
* The MWF calculation defines the force on each individual load cell.
** If Angle B is below horizontal use + in calculation. If Angle B is above determine the maximum working force (MWF)
horizontal use – in calculation. MWF = 2T x K x sin (A/2) +
_ W sin (B) that is exerted on each transducer. Select a trans-
2 ducer rating that exceeds the MWF.
MWF = Maximum Working Force (lbs) The calculation should be performed using
T = Maximum Total Tension (lbs) the minimum tension. The resulting value indicates
CARTRIDGE-STYLE SIZING CALCULATION
K = Transient Tension Overload Factor what the force output will be at the lowest tension.
2T x K x sin (A/2) +_ W x sin (B)** (normally 1.4 to 2.0) If it is a very small percentage of the transducer
MWF* = ––––––––––––––––––––––––––––––––––––– A = Wrap Angle
rating (typically less than 1/20 or 1/30 the rating),
2 B = Angle of Tension Force
you may need to increase the wrap angle, re-orient
MWF = Maximum Working Force (lbs.) W = Weight of Roller (lbs)
the web wrap, or reduce the roller weight to
(used to select the proper force rating of achieve a usable measurement at low tension.
According to Don Strenio, sensors and
the transducer) Strenio adds, "To select and size the right
controls product manager for Cleveland Motion
K = Transient Tension Overload Factor Controls, the user needs to proceed as follows transducer for the application requires careful
(normally between 1.4 and 2.0) in order to determine the parameters used in the attention to detail. You need to totally understand
T = Maximum Total Tension (lbs.) equation: the application and then calculate a basic equation
A = Wrap Angle (degrees) First, make a sketch that shows where the for each transducer. The equation is only the first
B = Angle of Tension Force (degrees) web enters and exits as it wraps around the step. In fact, you should never order a transducer
W = Weight of Roller roller. (Refer to the diagram below). The point without consulting the supplier first. The success
where the web touches the roller as it enters and of the application often depends on the extent
* The MWF calculation defines the force on each individual load cell.
** If Angle B is below horizontal use + in calculation. If Angle B is above
exits the wrap is referred to as the tangent. to which the user and supplier work together in
horizontal use – in calculation. Draw a radius from the center of the circle and addressing the application. Once the supplier
perpendicular to each tangent at entry and exit. receives your information, you need to rely on
These lines define angle A, which is the Wrap Angle. the supplier’s application experience to perform
SIZING THE
Figure 14 - Continued To determine angle B, draw a line that bisects the calculations, evaluate the requirement, and if
angle A. The angle that this line makes with the necessary, recommend machine design changes
TRANSDUCER Q: How Are Sizing Formulas Applied? horizontal is angle B—the Angle of Tension Force. or alternate methods."
If angle B is below the horizontal, use positive (+)
During the process, it was found that the
FOR THE LOAD Figure 15 discusses how the sizing formula was utilized on an application in the calculation, if angle B is above the horizontal,
main draw rollers (which are extremely important
use negative (-) in the calculation.
for RR Donnelley and Sons. It also explains how to determine the wrap for maintaining steady tension on the entire web)
REQUIREMENTS
angle and angle of tension force. The initial calculation indicated that were too heavy to take full advantage of the
the roller weight was too heavy to take full advantage of the load cell’s load cell’s capabilities. The output signal would not
be great enough to achieve optimal performance.
capability. The existing roller was replaced with a composite roller that
Based on Strenio’s recommendation, Donnelley
weighed much less. replaced the existing roller with a composite
roller, which weighed much less. By making this
change, Donnelley realized a significant improve-
ment in load-cell resolution, which resulted in a
significant improvement in the overall performance
of the closed-looped system.
Figure 15
18 19
w w w. C M C c o n t ro l s . c o m
A D V A N C E D W E B P R O C E S S C O N T R O L
SLIM CELL SIZING CALCULATION HOW TO SELECT THE Determine the Maximum Tension T, and the
MWF* = T x K x sin (A/2) +_ (W/2) x sin (B)** RIGHT TRANSDUCERS minimum tension that is required for your process.
If this is not known, consult your transducer supplier.
MWF = Maximum Working Force (lbs.) For RR Donnelley & Sons, two CMC SC The supplier should have charts that indicate typical
T = Maximum Total Tension (lbs.) Transducers are used on each tension roller, one tensions for various materials.
K = Transient Tension Overload Factor on each side. The web is wrapped around the Weigh the roller or calculate the roller weight
(normally 1.5 for most applications) tension roller. The Transducers measure the force to determine W. K is a safety factor that is used
A = Wrap Angle (degrees) that is exerted on the roller by the tension in the to account for tension transient overloads (a
B = Angle of Tension Force (degrees) moving web. The maximum working force (MWF) value of 1.4 to 2.0 is typical, depending on the
W = Weight of Roller exerted on the transducers is then calculated application.).
from the following equation. Insert those values into the equation to
* The MWF calculation defines the force on each individual load cell.
** If Angle B is below horizontal use + in calculation. If Angle B is above determine the maximum working force (MWF)
horizontal use – in calculation. MWF = 2T x K x sin (A/2) +
_ W sin (B) that is exerted on each transducer. Select a trans-
2 ducer rating that exceeds the MWF.
MWF = Maximum Working Force (lbs) The calculation should be performed using
T = Maximum Total Tension (lbs) the minimum tension. The resulting value indicates
CARTRIDGE-STYLE SIZING CALCULATION
K = Transient Tension Overload Factor what the force output will be at the lowest tension.
2T x K x sin (A/2) +_ W x sin (B)** (normally 1.4 to 2.0) If it is a very small percentage of the transducer
MWF* = ––––––––––––––––––––––––––––––––––––– A = Wrap Angle
rating (typically less than 1/20 or 1/30 the rating),
2 B = Angle of Tension Force
you may need to increase the wrap angle, re-orient
MWF = Maximum Working Force (lbs.) W = Weight of Roller (lbs)
the web wrap, or reduce the roller weight to
(used to select the proper force rating of achieve a usable measurement at low tension.
According to Don Strenio, sensors and
the transducer) Strenio adds, "To select and size the right
controls product manager for Cleveland Motion
K = Transient Tension Overload Factor Controls, the user needs to proceed as follows transducer for the application requires careful
(normally between 1.4 and 2.0) in order to determine the parameters used in the attention to detail. You need to totally understand
T = Maximum Total Tension (lbs.) equation: the application and then calculate a basic equation
A = Wrap Angle (degrees) First, make a sketch that shows where the for each transducer. The equation is only the first
B = Angle of Tension Force (degrees) web enters and exits as it wraps around the step. In fact, you should never order a transducer
W = Weight of Roller roller. (Refer to the diagram below). The point without consulting the supplier first. The success
where the web touches the roller as it enters and of the application often depends on the extent
* The MWF calculation defines the force on each individual load cell.
** If Angle B is below horizontal use + in calculation. If Angle B is above
exits the wrap is referred to as the tangent. to which the user and supplier work together in
horizontal use – in calculation. Draw a radius from the center of the circle and addressing the application. Once the supplier
perpendicular to each tangent at entry and exit. receives your information, you need to rely on
These lines define angle A, which is the Wrap Angle. the supplier’s application experience to perform
SIZING THE
Figure 14 - Continued To determine angle B, draw a line that bisects the calculations, evaluate the requirement, and if
angle A. The angle that this line makes with the necessary, recommend machine design changes
TRANSDUCER Q: How Are Sizing Formulas Applied? horizontal is angle B—the Angle of Tension Force. or alternate methods."
If angle B is below the horizontal, use positive (+)
During the process, it was found that the
FOR THE LOAD Figure 15 discusses how the sizing formula was utilized on an application in the calculation, if angle B is above the horizontal,
main draw rollers (which are extremely important
use negative (-) in the calculation.
for RR Donnelley and Sons. It also explains how to determine the wrap for maintaining steady tension on the entire web)
REQUIREMENTS
angle and angle of tension force. The initial calculation indicated that were too heavy to take full advantage of the
the roller weight was too heavy to take full advantage of the load cell’s load cell’s capabilities. The output signal would not
be great enough to achieve optimal performance.
capability. The existing roller was replaced with a composite roller that
Based on Strenio’s recommendation, Donnelley
weighed much less. replaced the existing roller with a composite
roller, which weighed much less. By making this
change, Donnelley realized a significant improve-
ment in load-cell resolution, which resulted in a
significant improvement in the overall performance
of the closed-looped system.
Figure 15
18 19
w w w. C M C c o n t ro l s . c o m
A D V A N C E D W E B P R O C E S S C O N T R O L
WHAT WHAT TECHNIQUES CAN GET THE MOST A lower output signal results if the transducer is not installed so that the WHAT
FROM MY LOAD CELLS? arrow is aligned with the bisector of the wrap angle. Generally, "eyeballing"
TECHNIQUES TECHNIQUES
is sufficient to achieve proper alignment. The resultant signal output is a
CAN GET THE MOST function of the sin of the included angle between the direction of the CAN GET THE MOST
Note: These examples and explanations utilize cartridge style transducers. force and the surface of the beam. Being 5 degrees off in alignment
FROM MY LOAD The formulas for other styles may be different so the specifics may change, results in less than a 1% drop in signal strength from the maximum. FROM MY LOAD
but the principles for application are the same. Being 15 degrees off results in only a 4% drop and 30 degrees results
CELLS? CELLS?
in 13% drop.
Orient the Load Cell Properly
A= WRAP
Load cells require that they be oriented properly. This is because the ANGLE
force exerted on the roller due to the tension in the material must bend
the transducer beam in order produce a measurement. Refer to "How A/2 A/2
Do Load Cells Actually Work?"
The force due to the tension in the material always points along
the bisector of the angle of wrap (wrap angle). The bisector is the
line that splits the angle in half, also referred to as the Angle of Tension
W
Force. If the bisector of the wrap angle is vertical and the material is EB EB
pulling down on the roller, the force points straight down. If the bisector W
of the wrap angle is vertical and the material is pulling up on the roller,
the force points straight up. Pulling horizontally on the roller is often
LABEL
used to negate the effect of the roller weight on the transducer—this
will be discussed later. (Refer to Figure 16)
ARROW
LOAD
Figure 17
( Transducer Mounting Orientation )
HANDBOOK
The load cell not only measures the force due to the tension in
the material but also due to the mass of the roller. The force
measured by the transducer due to the mass of the roller is known as
Figure 16 the tare weight. The tare weight is a function of the roller mass and the
( Pulling Orientation )
orientation of the transducer with respect to the gravitational force.
Gravity always pulls a mass toward the earth so the force due to gravity
There is an arrow on the coupling face of CMC’s Cartridge Style (weight) is always pointing vertically downward.
Transducer. Installation instructions require that the transducer
body be rotated so that the arrow is in line with the bisector of The force of gravity bends (deflects) the transducer beam the most
the wrap angle. (Refer to Figure 17) When oriented in this manner when it is perpendicular to it. The greater the deflection, the greater the
the force is always perpendicular (at right angles) to the beam. Maximum output signal. When the transducer is oriented in this manner the
bending (deflection) of the beam occurs when the force is exerted at a output signal due to gravity is always at it’s strongest (maximum) for
right angle to the beam surface. The larger the deflection the greater a given mass. In this situation the tare weight is the weight of the roller.
the output signal (measurement). When the transducer is oriented in For the Cartridge Style Transducer this occurs when it is oriented so
this manner, the output signal is always at its strongest (maximum) for a that the arrow on the coupling face is pointing vertically up or down.
given force. This means that for a given tension and wrap angle no
other orientation will yield as strong a measurement.
20 21
w w w. C M C c o n t ro l s . c o m
A D V A N C E D W E B P R O C E S S C O N T R O L
WHAT WHAT TECHNIQUES CAN GET THE MOST A lower output signal results if the transducer is not installed so that the WHAT
FROM MY LOAD CELLS? arrow is aligned with the bisector of the wrap angle. Generally, "eyeballing"
TECHNIQUES TECHNIQUES
is sufficient to achieve proper alignment. The resultant signal output is a
CAN GET THE MOST function of the sin of the included angle between the direction of the CAN GET THE MOST
Note: These examples and explanations utilize cartridge style transducers. force and the surface of the beam. Being 5 degrees off in alignment
FROM MY LOAD The formulas for other styles may be different so the specifics may change, results in less than a 1% drop in signal strength from the maximum. FROM MY LOAD
but the principles for application are the same. Being 15 degrees off results in only a 4% drop and 30 degrees results
CELLS? CELLS?
in 13% drop.
Orient the Load Cell Properly
A= WRAP
Load cells require that they be oriented properly. This is because the ANGLE
force exerted on the roller due to the tension in the material must bend
the transducer beam in order produce a measurement. Refer to "How A/2 A/2
Do Load Cells Actually Work?"
The force due to the tension in the material always points along
the bisector of the angle of wrap (wrap angle). The bisector is the
line that splits the angle in half, also referred to as the Angle of Tension
W
Force. If the bisector of the wrap angle is vertical and the material is EB EB
pulling down on the roller, the force points straight down. If the bisector W
of the wrap angle is vertical and the material is pulling up on the roller,
the force points straight up. Pulling horizontally on the roller is often
LABEL
used to negate the effect of the roller weight on the transducer—this
will be discussed later. (Refer to Figure 16)
ARROW
LOAD
Figure 17
( Transducer Mounting Orientation )
HANDBOOK
The load cell not only measures the force due to the tension in
the material but also due to the mass of the roller. The force
measured by the transducer due to the mass of the roller is known as
Figure 16 the tare weight. The tare weight is a function of the roller mass and the
( Pulling Orientation )
orientation of the transducer with respect to the gravitational force.
Gravity always pulls a mass toward the earth so the force due to gravity
There is an arrow on the coupling face of CMC’s Cartridge Style (weight) is always pointing vertically downward.
Transducer. Installation instructions require that the transducer
body be rotated so that the arrow is in line with the bisector of The force of gravity bends (deflects) the transducer beam the most
the wrap angle. (Refer to Figure 17) When oriented in this manner when it is perpendicular to it. The greater the deflection, the greater the
the force is always perpendicular (at right angles) to the beam. Maximum output signal. When the transducer is oriented in this manner the
bending (deflection) of the beam occurs when the force is exerted at a output signal due to gravity is always at it’s strongest (maximum) for
right angle to the beam surface. The larger the deflection the greater a given mass. In this situation the tare weight is the weight of the roller.
the output signal (measurement). When the transducer is oriented in For the Cartridge Style Transducer this occurs when it is oriented so
this manner, the output signal is always at its strongest (maximum) for a that the arrow on the coupling face is pointing vertically up or down.
given force. This means that for a given tension and wrap angle no
other orientation will yield as strong a measurement.
20 21
w w w. C M C c o n t ro l s . c o m
A D V A N C E D W E B P R O C E S S C O N T R O L
WHAT The tare weight adds or subtracts to the output signal produced by the opposite direction of the tension force and is negative. It subtracts from WHAT
tension force. As part of the calibration procedure the tare weight is the tension force to decrease the total load on the transducer.
TECHNIQUES TECHNIQUES
zeroed out so that only the signal due to tension is measured. This is
CAN GET THE MOST accomplished by various means in the electronic amplifiers or controllers, Example: CAN GET THE MOST
either automatically or by adjusting a potentiometer. The maximum tension in the material is 50 lb. and the roller
FROM MY LOAD weight is 60 lb. The wrap angle is 180 degrees. Select the FROM MY LOAD
If the output signal due to the tare weight is too great, less of the Cartridge Style Transducer. Calculate the MWF for different
CELLS? CELLS?
total transducer output signal can be utilized for measuring the orientations. Ignore the safety factor, K, by making K=1.
tension force. This is especially important to consider when the roll weight
is large when compared to the required tension. If the force is pulling straight down, a Maximum Working Force
(MWF) of 80 lb. per transducer is calculated. 50 lb. is the force due
As a rule of thumb the tare weight should be no greater than 2/3 of to the tension and 30 lb. is the tare weight. The tare weight is in the
the transducer load rating (MWF). This leaves enough signal to measure same direction as the tension force, so it is added. The closest transducer
the tension load. There are exceptions to this if the tension range is rating that meets or exceeds the MWF is 100 lb.
small (2:1, 4:1). For a large tension range (20:1, 30:1) the tare weight
must be reduced to zero or used to extend the transducer range by If the web path is changed so the force is pulling straight up, a
working in the opposite direction of the load. Maximum Working Force (MWF) of 20 lb. per transducer is
calculated. 50 lb. is the force due to the tension and 30 lb. is the tare
If the tare weight is too large, either the roller weight must be reduced or weight. The tare weight is in the opposite direction of the tension
the web path changed so that the transducer can be oriented differently. force, so it is subtracted. The closest transducer rating that meets or
Constructing the roller from aluminum or composite material will reduce exceeds the MWF is 25 lb. Pulling up on the roll allows a lower MWF rat-
the roller weight. ing to be selected which results in a higher transducer output and
more sensitivity. However, the 25 lb. MWF transducer is not accept-
Calculate the Tare Weight and Make it Work For You able because the tare weight of 30 lb. exceeds the transducer rating
of 25 lb. Never choose a load cell rating that is less than the tare
The tare weight calculation is part of the sizing formula. Refer to the sizing weight it supports, otherwise overloading may damage it. A 50 lb. MWF
formula and orientation diagram for the Cartridge Style Transducer in rating is the next available size so it is selected.
Figure 14. The term in the equation +/- W sin (B) /2 is the gravitational
force exerted on the transducer beam due to the roller mass and is By pulling up instead of down on the roll the transducer size has been
referred to as the tare weight. There is an arrow on the coupling face of reduced from 100 lb. to 50 lb. The sensitivity has increased twofold and
the cartridge transducer. During installation the transducer is rotated so we have increased the ability to measure lower tensions thus increasing
that the arrow is in line with the bisector of the wrap angle. This bisector the range of tensions that we are able to measure. A transducer with a
is the line from which the Angle B (Angle of Tension Force) is determined. lower MWF force rating is more sensitive to lighter loads than one with a
HANDBOOK
The other side of angle B is the horizontal line. W is the roller weight. higher MWF rating. For the greatest possible tension range choose
For any orientation Angle B can always be referenced from the horizontal, the transducer with the lowest possible force (MWF) rating.
so B is between 0 and 90 degrees.
If the force is pulling up, the beam moves downward from its neutral
Pull up on the roll to extend the range of the transducer (Refer position when the 30 lb. roll weight is applied and then moves upward
to Figure 16). When B is 90 degrees, the force is either pulling straight past its neutral position when the 50 lb. tension force is applied. (Refer
up or straight down on the roller. The sin of 90 degrees is 1. Inserting B to Figure 18) The strain gages are bipolar and give a signal (the signal
= 90 degrees into the equation yields a tare weight of +/- W/2. This is can be offset or zeroed with the electronics) if the beam is deflected
half the weight of the roller. The weight of the roller, W, is divided by 2 down or up. The transducer can operate at up to + 50 lb. or –50 lb. By
since there are two transducers supporting this roller. pulling against the roll weight we can extend the effective measuring
range of the transducer up to double its rating in some situations.
When the tension pulls down on the roller the tare weight W/2 acts in
the same direction as the tension force and is positive. It adds to the The recommended orientation for most applications is a 180-degree
tension force to increase the total load on the transducer. wrap angle pulling straight up on the roller. This gets maximum utiliza-
tion from the transducer. (Refer to Figure 16) Following this rule is
By pulling up on the transducer, the roller weight can work for you. generally a good idea. However, many times its is not possible to
When the tension pulls up on the roller the tare weight W/2 acts in the achieve this orientation or wrap angle.
22 23
w w w. C M C c o n t ro l s . c o m
A D V A N C E D W E B P R O C E S S C O N T R O L
WHAT The tare weight adds or subtracts to the output signal produced by the opposite direction of the tension force and is negative. It subtracts from WHAT
tension force. As part of the calibration procedure the tare weight is the tension force to decrease the total load on the transducer.
TECHNIQUES TECHNIQUES
zeroed out so that only the signal due to tension is measured. This is
CAN GET THE MOST accomplished by various means in the electronic amplifiers or controllers, Example: CAN GET THE MOST
either automatically or by adjusting a potentiometer. The maximum tension in the material is 50 lb. and the roller
FROM MY LOAD weight is 60 lb. The wrap angle is 180 degrees. Select the FROM MY LOAD
If the output signal due to the tare weight is too great, less of the Cartridge Style Transducer. Calculate the MWF for different
CELLS? CELLS?
total transducer output signal can be utilized for measuring the orientations. Ignore the safety factor, K, by making K=1.
tension force. This is especially important to consider when the roll weight
is large when compared to the required tension. If the force is pulling straight down, a Maximum Working Force
(MWF) of 80 lb. per transducer is calculated. 50 lb. is the force due
As a rule of thumb the tare weight should be no greater than 2/3 of to the tension and 30 lb. is the tare weight. The tare weight is in the
the transducer load rating (MWF). This leaves enough signal to measure same direction as the tension force, so it is added. The closest transducer
the tension load. There are exceptions to this if the tension range is rating that meets or exceeds the MWF is 100 lb.
small (2:1, 4:1). For a large tension range (20:1, 30:1) the tare weight
must be reduced to zero or used to extend the transducer range by If the web path is changed so the force is pulling straight up, a
working in the opposite direction of the load. Maximum Working Force (MWF) of 20 lb. per transducer is
calculated. 50 lb. is the force due to the tension and 30 lb. is the tare
If the tare weight is too large, either the roller weight must be reduced or weight. The tare weight is in the opposite direction of the tension
the web path changed so that the transducer can be oriented differently. force, so it is subtracted. The closest transducer rating that meets or
Constructing the roller from aluminum or composite material will reduce exceeds the MWF is 25 lb. Pulling up on the roll allows a lower MWF rat-
the roller weight. ing to be selected which results in a higher transducer output and
more sensitivity. However, the 25 lb. MWF transducer is not accept-
Calculate the Tare Weight and Make it Work For You able because the tare weight of 30 lb. exceeds the transducer rating
of 25 lb. Never choose a load cell rating that is less than the tare
The tare weight calculation is part of the sizing formula. Refer to the sizing weight it supports, otherwise overloading may damage it. A 50 lb. MWF
formula and orientation diagram for the Cartridge Style Transducer in rating is the next available size so it is selected.
Figure 14. The term in the equation +/- W sin (B) /2 is the gravitational
force exerted on the transducer beam due to the roller mass and is By pulling up instead of down on the roll the transducer size has been
referred to as the tare weight. There is an arrow on the coupling face of reduced from 100 lb. to 50 lb. The sensitivity has increased twofold and
the cartridge transducer. During installation the transducer is rotated so we have increased the ability to measure lower tensions thus increasing
that the arrow is in line with the bisector of the wrap angle. This bisector the range of tensions that we are able to measure. A transducer with a
is the line from which the Angle B (Angle of Tension Force) is determined. lower MWF force rating is more sensitive to lighter loads than one with a
HANDBOOK
The other side of angle B is the horizontal line. W is the roller weight. higher MWF rating. For the greatest possible tension range choose
For any orientation Angle B can always be referenced from the horizontal, the transducer with the lowest possible force (MWF) rating.
so B is between 0 and 90 degrees.
If the force is pulling up, the beam moves downward from its neutral
Pull up on the roll to extend the range of the transducer (Refer position when the 30 lb. roll weight is applied and then moves upward
to Figure 16). When B is 90 degrees, the force is either pulling straight past its neutral position when the 50 lb. tension force is applied. (Refer
up or straight down on the roller. The sin of 90 degrees is 1. Inserting B to Figure 18) The strain gages are bipolar and give a signal (the signal
= 90 degrees into the equation yields a tare weight of +/- W/2. This is can be offset or zeroed with the electronics) if the beam is deflected
half the weight of the roller. The weight of the roller, W, is divided by 2 down or up. The transducer can operate at up to + 50 lb. or –50 lb. By
since there are two transducers supporting this roller. pulling against the roll weight we can extend the effective measuring
range of the transducer up to double its rating in some situations.
When the tension pulls down on the roller the tare weight W/2 acts in
the same direction as the tension force and is positive. It adds to the The recommended orientation for most applications is a 180-degree
tension force to increase the total load on the transducer. wrap angle pulling straight up on the roller. This gets maximum utiliza-
tion from the transducer. (Refer to Figure 16) Following this rule is
By pulling up on the transducer, the roller weight can work for you. generally a good idea. However, many times its is not possible to
When the tension pulls up on the roller the tare weight W/2 acts in the achieve this orientation or wrap angle.
22 23
w w w. C M C c o n t ro l s . c o m
A D V A N C E D W E B P R O C E S S C O N T R O L
WHAT When B is 0 degrees the force is pulling horizontally on the roller. WHAT
HANDBOOK
Style Transducer in Figure 14. The term in the equation 2T x sin (A/2)/2
is the force exerted by the tension in the material as it wraps around the
roller. (The term is divided by 2 since there are two transducers supporting
this roller which divides the total load. Ignore the safety factor, K, by
making K=1.
The tension, T, pulls in opposite directions away from the roller, and this
puts double the load or 2T on the roller. The portion of tension that is
transmitted to the roller and the transducer is dependent upon the
amount of wrap around the roller. The amount of wrap is referred
to as the wrap angle. This angle is determined by drawing a line
from the center of the roller perpendicular to where the web first
Figure 18-C touches the roller as it enters and another where it last touches as it
( 30 LB Roller Weight and 50 LB Tension Force ) exits. The angle in between is defined as A, the wrap angle.
24 25
w w w. C M C c o n t ro l s . c o m
A D V A N C E D W E B P R O C E S S C O N T R O L
WHAT When B is 0 degrees the force is pulling horizontally on the roller. WHAT
HANDBOOK
Style Transducer in Figure 14. The term in the equation 2T x sin (A/2)/2
is the force exerted by the tension in the material as it wraps around the
roller. (The term is divided by 2 since there are two transducers supporting
this roller which divides the total load. Ignore the safety factor, K, by
making K=1.
The tension, T, pulls in opposite directions away from the roller, and this
puts double the load or 2T on the roller. The portion of tension that is
transmitted to the roller and the transducer is dependent upon the
amount of wrap around the roller. The amount of wrap is referred
to as the wrap angle. This angle is determined by drawing a line
from the center of the roller perpendicular to where the web first
Figure 18-C touches the roller as it enters and another where it last touches as it
( 30 LB Roller Weight and 50 LB Tension Force ) exits. The angle in between is defined as A, the wrap angle.
24 25
w w w. C M C c o n t ro l s . c o m
A D V A N C E D W E B P R O C E S S C O N T R O L
WHAT The portion of tension through the wrap angle is sin (A/2). The maximum Be Judicious in Assigning the Safety Factor WHAT
value for the sin is 1 and this occurs when the angle A is 180 degrees
TECHNIQUES TECHNIQUES
(sin (180/2) = sin (90) =1). The largest amount of tension is trans- The K factor is assigned to ensure that the MWF rating of the transducer
CAN GET THE MOST mitted to the roller when the wrap angle is 180 degrees. When A is high enough to protect it from transient overloads. Overload conditions CAN GET THE MOST
is 0 degrees there is no wrap around the roller and the tension force is zero. may damage the transducers. Some transducers are rated for higher
FROM MY LOAD overloads than others. The recommend overload rating to use for the FROM MY LOAD
For typical applications, and especially for low tension, it is Cartridge Style Transducer is 150% of the MWF. A K of 1.4 to 2 is typically
CELLS? CELLS?
desirable to make the wrap angle as large as possible. This produces used for these transducers, which extends the overload protection to
the greatest tension force giving more signal output resulting in a better 210% and 300% effectively. It is not always necessary to assign a K
measurement. value greater that 1; it depends upon the application and the transducer
overload rating. Overload limits for the UPB Washdown Duty LC are
Many machine designers use a minimum of 30 degrees of wrap as a 500% and the Slim Cell Transducer are as high as 1000%.
rule of thumb. A wrap angle of 30 degrees transmits 25% of the line
tension to the transducer. This is still a significant value so they know The amount of conservatism that is placed on the maximum
the signal will be manageable. In most cases, this also gives enough tension value and the method in which the machine is controlled
wrap to ensure that the material stays in contact with the roller surface. needs to be taken into consideration when assigning the K value.
With light material, running at low tension and at high speeds, air may Making the K value too large may oversize (too large of a MWF) the
draft under the material causing it to rise and lose contact with the transducer limiting the low end of the effective tension range. Of course,
roller surface. Transducers are applied at much lower angles of wrap, undersizing (too small of a MWF) can lead to damaged transducers.
but the application requires scrutiny to ensure proper performance. When a large tension range is required (20:1, 30:1), oversizing the
transducer limits its low-end performance. When a small tension range
For some applications it is desirable to slightly decrease the wrap angle is required (2:1, 4:1), oversizing the transducers gives it extra protection.
in order to use a smaller transducer (smaller MWF rating). This is generally
considered when large tension ranges are required. In this case, we Be Realistic About Tension Control and Over What Range
want to use the entire transducer output signal in order to get maximum
resolution. How well tension can be controlled and over what range depends
upon many factors other than how well the load cells perform their
Maintain a Fixed Angle of Wrap Throughout the Process measurements. Some of these factors are the mechanical design of the
machine, mechanical wear of the components, line speed, and the system
If the angle of wrap varies, the tension force on the transducer changes. response (mechanical and electrical). All systems have natural resonant
This results in inaccurate measurements. Only use transducers on a roller frequencies that limit their ability to be controlled and to respond to
where the wrap angle is fixed. (Refer to Figure 19) corrective changes. (Refer to Figure 20) System engineers explain that
attempting to control tension above a 20:1 or 30:1 range and achieve
HANDBOOK
acceptable tolerances is extremely difficult. Some system integrators
won’t accept jobs specifying a tension range over 10:1. Although the
load cell signal output is linear all the way down to zero, CMC doesn’t
recommend exceeding a 20:1 or 30:1 tension range from an individual
load cell. These applications require special attention. Steps can be taken
to extend the measuring range such as routing the web over an idler
roller to change the wrap angle. (Refer to Figure 21) Most applications
require much less range than this—4:1, 8:1.
Figure 19
26 ( Where to Mount Tension Transducers ) 27
w w w. C M C c o n t ro l s . c o m
A D V A N C E D W E B P R O C E S S C O N T R O L
WHAT The portion of tension through the wrap angle is sin (A/2). The maximum Be Judicious in Assigning the Safety Factor WHAT
value for the sin is 1 and this occurs when the angle A is 180 degrees
TECHNIQUES TECHNIQUES
(sin (180/2) = sin (90) =1). The largest amount of tension is trans- The K factor is assigned to ensure that the MWF rating of the transducer
CAN GET THE MOST mitted to the roller when the wrap angle is 180 degrees. When A is high enough to protect it from transient overloads. Overload conditions CAN GET THE MOST
is 0 degrees there is no wrap around the roller and the tension force is zero. may damage the transducers. Some transducers are rated for higher
FROM MY LOAD overloads than others. The recommend overload rating to use for the FROM MY LOAD
For typical applications, and especially for low tension, it is Cartridge Style Transducer is 150% of the MWF. A K of 1.4 to 2 is typically
CELLS? CELLS?
desirable to make the wrap angle as large as possible. This produces used for these transducers, which extends the overload protection to
the greatest tension force giving more signal output resulting in a better 210% and 300% effectively. It is not always necessary to assign a K
measurement. value greater that 1; it depends upon the application and the transducer
overload rating. Overload limits for the UPB Washdown Duty LC are
Many machine designers use a minimum of 30 degrees of wrap as a 500% and the Slim Cell Transducer are as high as 1000%.
rule of thumb. A wrap angle of 30 degrees transmits 25% of the line
tension to the transducer. This is still a significant value so they know The amount of conservatism that is placed on the maximum
the signal will be manageable. In most cases, this also gives enough tension value and the method in which the machine is controlled
wrap to ensure that the material stays in contact with the roller surface. needs to be taken into consideration when assigning the K value.
With light material, running at low tension and at high speeds, air may Making the K value too large may oversize (too large of a MWF) the
draft under the material causing it to rise and lose contact with the transducer limiting the low end of the effective tension range. Of course,
roller surface. Transducers are applied at much lower angles of wrap, undersizing (too small of a MWF) can lead to damaged transducers.
but the application requires scrutiny to ensure proper performance. When a large tension range is required (20:1, 30:1), oversizing the
transducer limits its low-end performance. When a small tension range
For some applications it is desirable to slightly decrease the wrap angle is required (2:1, 4:1), oversizing the transducers gives it extra protection.
in order to use a smaller transducer (smaller MWF rating). This is generally
considered when large tension ranges are required. In this case, we Be Realistic About Tension Control and Over What Range
want to use the entire transducer output signal in order to get maximum
resolution. How well tension can be controlled and over what range depends
upon many factors other than how well the load cells perform their
Maintain a Fixed Angle of Wrap Throughout the Process measurements. Some of these factors are the mechanical design of the
machine, mechanical wear of the components, line speed, and the system
If the angle of wrap varies, the tension force on the transducer changes. response (mechanical and electrical). All systems have natural resonant
This results in inaccurate measurements. Only use transducers on a roller frequencies that limit their ability to be controlled and to respond to
where the wrap angle is fixed. (Refer to Figure 19) corrective changes. (Refer to Figure 20) System engineers explain that
attempting to control tension above a 20:1 or 30:1 range and achieve
HANDBOOK
acceptable tolerances is extremely difficult. Some system integrators
won’t accept jobs specifying a tension range over 10:1. Although the
load cell signal output is linear all the way down to zero, CMC doesn’t
recommend exceeding a 20:1 or 30:1 tension range from an individual
load cell. These applications require special attention. Steps can be taken
to extend the measuring range such as routing the web over an idler
roller to change the wrap angle. (Refer to Figure 21) Most applications
require much less range than this—4:1, 8:1.
Figure 19
26 ( Where to Mount Tension Transducers ) 27
w w w. C M C c o n t ro l s . c o m
A D V A N C E D W E B P R O C E S S C O N T R O L
SENSING A primary consideration in tension sensing is that the path of the moving
CAN GET THE MOST
ROLLER web be disrupted as little as possible as the measurement is being
FROM MY LOAD taken. This means that the deflection of the load cell must be minimal.
The more deflection the more likely the web path will be disturbed and
HANDBOOK
CELLS? not track properly. CMC load cells exhibit very little deflection at
WEB
the rated tension load, typically only between .002 to .004 inches.
In addition, their twin beam design (Refer to Figure 4) ensures that
PATH A any beam deflection is perpendicular to the web path to prevent
(More Sensitive) steering to one side. Brands from some manufacturers typically allow
as much as .10 inches deflection at full load. Also, load cells using
IDILER SENSING
ROLLER ROLLER
strain gages have significantly less deflection than those using LVDTs.
WEB
PATH B
(Less Sensitive)
Figure 21
( Method to Double the Tension Range of a Sensing Roll )
28 29
w w w. C M C c o n t ro l s . c o m
A D V A N C E D W E B P R O C E S S C O N T R O L
SENSING A primary consideration in tension sensing is that the path of the moving
CAN GET THE MOST
ROLLER web be disrupted as little as possible as the measurement is being
FROM MY LOAD taken. This means that the deflection of the load cell must be minimal.
The more deflection the more likely the web path will be disturbed and
HANDBOOK
CELLS? not track properly. CMC load cells exhibit very little deflection at
WEB
the rated tension load, typically only between .002 to .004 inches.
In addition, their twin beam design (Refer to Figure 4) ensures that
PATH A any beam deflection is perpendicular to the web path to prevent
(More Sensitive) steering to one side. Brands from some manufacturers typically allow
as much as .10 inches deflection at full load. Also, load cells using
IDILER SENSING
ROLLER ROLLER
strain gages have significantly less deflection than those using LVDTs.
WEB
PATH B
(Less Sensitive)
Figure 21
( Method to Double the Tension Range of a Sensing Roll )
28 29
w w w. C M C c o n t ro l s . c o m
A D V A N C E D W E B P R O C E S S C O N T R O L
WHAT SHOULD Q: Will the Load Cell Allow for Shaft Misalignment? Q: Is the Load Cell’s Signal Linear and Repeatable? WHAT SHOULD
HANDBOOK
Q: How Responsive is the Load Cell? bearing that is chosen must be one that is designed to accommodate shaft
expansion. When the load cell is coupled to the roller shaft, the load cell
The load cell must respond quickly to tension changes. This is especially must be able to accommodate the shaft expansion due to temperature
true when it is being utilized in closed-loop applications. CMC load changes. CMC load cells are designed to accommodate 0.10 inches
cells are designed to have a high natural frequency; they respond of shaft expansion per transducer (Refer to Figure 4). Where two
quickly to changing tension in the web. CMC electronics such as load cells are utilized, shaft expansion of 0.20 inches can be accommodated.
amplifiers, indicators, and controllers are also designed to accommodate
this rapid response. Brands from other manufacturers have high inertia, Many manufactures require that one end of the roller shaft be tightened
which limits their response capability. The supplier should be able to to a transducer coupling and the other end be free to float in the transducer
calculate the response of their load cell in your application. Stay away coupling. While this may relieve the stress due to shaft expansion it
from designs that require movement of substantial mass; they will yield requires special mounting procedures and the use of "feeler gages" to
a sluggish response. set the appropriate gaps. Insuring that the gap is even may require the
use of shims. Having to adhere to these requirements places much
responsibility on the expertise and judgment of the installer. This can
lead to improper installation or inconsistencies especially if the transducers
are removed and then reinstalled (for roller maintenance—replacing
bearings in the rollers) by someone other than the initial installer.
30 31
w w w. C M C c o n t ro l s . c o m
A D V A N C E D W E B P R O C E S S C O N T R O L
WHAT SHOULD Q: Will the Load Cell Allow for Shaft Misalignment? Q: Is the Load Cell’s Signal Linear and Repeatable? WHAT SHOULD
HANDBOOK
Q: How Responsive is the Load Cell? bearing that is chosen must be one that is designed to accommodate shaft
expansion. When the load cell is coupled to the roller shaft, the load cell
The load cell must respond quickly to tension changes. This is especially must be able to accommodate the shaft expansion due to temperature
true when it is being utilized in closed-loop applications. CMC load changes. CMC load cells are designed to accommodate 0.10 inches
cells are designed to have a high natural frequency; they respond of shaft expansion per transducer (Refer to Figure 4). Where two
quickly to changing tension in the web. CMC electronics such as load cells are utilized, shaft expansion of 0.20 inches can be accommodated.
amplifiers, indicators, and controllers are also designed to accommodate
this rapid response. Brands from other manufacturers have high inertia, Many manufactures require that one end of the roller shaft be tightened
which limits their response capability. The supplier should be able to to a transducer coupling and the other end be free to float in the transducer
calculate the response of their load cell in your application. Stay away coupling. While this may relieve the stress due to shaft expansion it
from designs that require movement of substantial mass; they will yield requires special mounting procedures and the use of "feeler gages" to
a sluggish response. set the appropriate gaps. Insuring that the gap is even may require the
use of shims. Having to adhere to these requirements places much
responsibility on the expertise and judgment of the installer. This can
lead to improper installation or inconsistencies especially if the transducers
are removed and then reinstalled (for roller maintenance—replacing
bearings in the rollers) by someone other than the initial installer.
30 31
w w w. C M C c o n t ro l s . c o m
A D V A N C E D W E B P R O C E S S C O N T R O L
WHAT SHOULD Q: Will the Load Cell be Reliable and Durable? NOTES
I LOOK FOR IN A
Look at the construction of the load cell. Is it open or sealed? Dust
LOAD CELL? entering into the sensing elements can shorten the operating life. Is
the body cast, machined, or is it made from sheet metal. Sheet metal
designs are not nearly as rugged. Does the design require moving parts,
mechanical springs, or offsets? These wear over time and present
calibration problems. How reputable is the load cell manufacturer?
How long has the manufacturer been in business? Who have the best
companies been using? A good reputation is generally derived from
producing a reliable product.
SUMMARY
SUMMARY
The more you know about selecting and sizing load cells the better your
chance for success in your web tension application. It is important to
understand why and how load cells are to be applied in your control scheme.
Select the style that best fits your requirements. Use the appropriate techniques
to get the most out of your load cell. Size the transducer to determine the
HANDBOOK
load rating that best meets your tension range. Ensure that it has been
designed to meet your performance requirements and will be both reliable
and durable. Doing all of this will give years of outstanding, reliable performance
from your load cell.
32 33
w w w. C M C c o n t ro l s . c o m
A D V A N C E D W E B P R O C E S S C O N T R O L
WHAT SHOULD Q: Will the Load Cell be Reliable and Durable? NOTES
I LOOK FOR IN A
Look at the construction of the load cell. Is it open or sealed? Dust
LOAD CELL? entering into the sensing elements can shorten the operating life. Is
the body cast, machined, or is it made from sheet metal. Sheet metal
designs are not nearly as rugged. Does the design require moving parts,
mechanical springs, or offsets? These wear over time and present
calibration problems. How reputable is the load cell manufacturer?
How long has the manufacturer been in business? Who have the best
companies been using? A good reputation is generally derived from
producing a reliable product.
SUMMARY
SUMMARY
The more you know about selecting and sizing load cells the better your
chance for success in your web tension application. It is important to
understand why and how load cells are to be applied in your control scheme.
Select the style that best fits your requirements. Use the appropriate techniques
to get the most out of your load cell. Size the transducer to determine the
HANDBOOK
load rating that best meets your tension range. Ensure that it has been
designed to meet your performance requirements and will be both reliable
and durable. Doing all of this will give years of outstanding, reliable performance
from your load cell.
32 33
w w w. C M C c o n t ro l s . c o m
A D V A N C E D W E B P R O C E S S C O N T R O L
Used for Used for For use For use Min. Load Max. Load Typical Inside Outside Above Washdown- For use in For use in Why would I Select this Typical Applications Price
Wide Narrow with with Rating Rating Overload Machine Machine Machine Duty, Vacuums High Transducer over the Others? Comparison
Webs Webs Stationary Rotating Offered Offered Rating Frame Frame Frame Corrosive (Modified) Temperatures *Low End
(Over (Under ( Dead ) ( Live) (LB.) (LB.) ( %) (Stud or ( Pillow and (Modified) ** Mid Range
20 in.) 20 in.) Shafts Shafts Flange Block Chemical ***High End
Mount) Mount) Resisting
Cantilevered 150 - For use with Cantilevered Wire and Cable, Ribbon,
CR
• • 5 150
300%
• • Pulleys, Good Value Textiles *
Figure 22 Standard Features for all Transducers: * Transducers are offered in variety of load ratings. They must be properly sized for the tension load. Figure 22
– Typical Tension Range- 20/1 to 30/1 ( Based on Proper Load Cell Sizing ) Refer to the appropriate transducer data sheet for sizing formulas and available load ratings.
– Temperature Range -0-200 degrees F
** Mounting kits are required for some mounting configurations. Refer to the appropriate
– Load Cells can be oriented to measure the tension force in any direction transducer data sheet.
– UL certified for Intrinsically Safe applications
– CE label
34 35
w w w. C M C c o n t ro l s . c o m
A D V A N C E D W E B P R O C E S S C O N T R O L
Used for Used for For use For use Min. Load Max. Load Typical Inside Outside Above Washdown- For use in For use in Why would I Select this Typical Applications Price
Wide Narrow with with Rating Rating Overload Machine Machine Machine Duty, Vacuums High Transducer over the Others? Comparison
Webs Webs Stationary Rotating Offered Offered Rating Frame Frame Frame Corrosive (Modified) Temperatures *Low End
(Over (Under ( Dead ) ( Live) (LB.) (LB.) ( %) (Stud or ( Pillow and (Modified) ** Mid Range
20 in.) 20 in.) Shafts Shafts Flange Block Chemical ***High End
Mount) Mount) Resisting
Cantilevered 150 - For use with Cantilevered Wire and Cable, Ribbon,
CR
• • 5 150
300%
• • Pulleys, Good Value Textiles *
Figure 22 Standard Features for all Transducers: * Transducers are offered in variety of load ratings. They must be properly sized for the tension load. Figure 22
– Typical Tension Range- 20/1 to 30/1 ( Based on Proper Load Cell Sizing ) Refer to the appropriate transducer data sheet for sizing formulas and available load ratings.
– Temperature Range -0-200 degrees F
** Mounting kits are required for some mounting configurations. Refer to the appropriate
– Load Cells can be oriented to measure the tension force in any direction transducer data sheet.
– UL certified for Intrinsically Safe applications
– CE label
34 35
A D V A N C E D W E B P R O C E S S C O N T R O L
36
Your Single Source For Web Tension Solutions
TENSION TRANSDUCERS
(Load Cells) DIN-RAIL AMPLIFIER
DIN-Rail
Amp Digital
Analog
0 - 10 VDC
Output
Dual Beams
Electrical Connector
MOTOR TACH TACH MOTOR
MOTOR DRIVE
Teflon-Coated OR CLUTCH
Temperature Alignment
Compensation Ball Joint
Network
For
Tension
Expansion Pin
Solutions
w w w . C M C c o n t r o l s . c o m
Your Single Source For Web Tension Solutions
ADVANCED WEB PROCESS CONTROL
H A N D B O O K ADVANCED WEB PROCESS CONTROL
CONTENTS
Clev
elan
d-Ki
dder ®
w w w . C M C c o n t r o l s . c o m w w w . C M C c o n t r o l s . c o m
All CMC Web Tension data sheets and manuals are available on our website. INTRODUCTION.................................................. 1 WHAT TECHNIQUES CAN GET THE MOST FROM MY
LOAD CELLS?...................................................... 20
THE FUNDAMENTALS OF WEB TENSION CONTROL.......... 1 • Orient the Load Cell Properly 20
How to Size and Select • What is Web Tension Control?
• What Requires Web Tension Control?
1
1
• Pay Attention to Roller Weight
• Calculate the Tare Weight and Make it Work For You
21
22