Tension Control: Maintaining constant tension with FMS products

Winding/unwinding, slitting, coating, printing and many other production processes require constant material tension.
With current drive solutions, sensor technology, bus systems and amplifiers tension control has become state of the art in converting lines, metal, paper and wire manufacturing and processing. Nowadays, tension measuring load cells are part of the standard equipment in running web production lines.

Closed loop tension control
Closed loop tension control principle
1 Force sensors measure the effective material tension.
2 The tension controller amplifies the measured signal from the force sensor and calculates an output value from the difference between the reference and feedback values.
3 The drive, brake, or clutch converts the output value from the tension controller into a corresponding torque or speed.
4 Constant tension in the process material can be maintained.

Defined, adjustable material tension
Reproducible values in physical units (Newtons, Pounds, etc.)
Known manufacturing conditions for finished products (quality recording capability)


Force Sensors (load cells):
Operational reliability and accuracy of measurement determine the productivity and quality of the processing. The type of processing, the material and factors such as temperature, humidity, and changing winding diameters would lead to continuous variations of the tension in the processed material – without closed loop tension control. FMS Force Sensors determine the tension and send a signal proportional to the tension to the FMS electronic units. The defining characteristics of the individually tested FMS Force Sensors are their capacity to withstand extreme overload conditions while maintaining the highest accuracy in the industry. This is accomplished through built-in mechanical stops to protect against overload and the utilization of foil-type strain gauges installed in a full Wheatstone Bridge configuration in each sensor to ensure the highest measuring accuracy. The sensors have to be determined for each application and FMS provides a wide range of sensors. The calculation can be done very easily with the Calculator.
Electronic Units:
FMS Tension Measuring Amplifiers and Closed Loop Tension Controllers process the signals from the Force Sensors and have each been specifically developed for use in tension control applications. The measuring amplifiers provide a 0..10V signal or can transmit the feedback values via a Bus System (ProfiBus, CAN or various Ethernet protocols), while the tension controllers generate a feedback value as well as an output value for a drive, brake, or clutch.

Tension measurement
FMS web tension measurement
The web tension in the material (FB) causes a resulting force in the direction of the bisecting line (FM) on a wrapped roller. The measurement of this force is a direct measure of the web tension. The feedback value can be sent to an FMS closed loop tension controller, which regulates a drive, brake, or clutch, ensuring constant material tension throughout the process.
Deutsch 中国 Italiano Español Português Pусский
A203 Series Force Measuring SensorsAMGZ Series Force Measuring JournalAnalog InstrumentAZS01B/04B BlueFlash Optical Edge SensorBKS 309.EIP Web Guide Controller with EtherNet/IP InterfaceBKS020 Splice TableBKS309 Series Digital Web Guide ControllerBMGZ Evaluation Electronic UnitBMGZ Measuring RollerC203 Force Measuring SensorCA203 Force Measuring SensorCMGZ309 Digital Tension ControllerCMGZ309.EIP Web Tension Controller with EtherNet/IP InterfaceCR Force Measuring RollerCZ205 Force Measuring JournalDLS2 Line and Edge SensorDMGZ Load CellEMGZ306A Compact Tension Measuring AmplifierEMGZ307 Extra Robust Tension Measuring AmplifierEMGZ309 Digital Tension Measuring AmplifierEMGZ309.EIP Measuring Amplifier with EtherNet/IP BusEMGZ310 Digital Tension Measuring AmplifierEMGZ310.ComACT Digital Tension Measuring Amplifier with Optional Operation via FMS ComACTEMGZ321 Left/right Tension Measuring AmplifierEMGZ321.EIP Left/Right Tension Measuring Amplifier with EtherNet/IP-BusEMGZ473.W Tension Measuring AmplifiersEMGZ474 PROFIBUS® Tension Measuring AmplifiersEMGZ491.ECAT Single-Channel Amplifier for ETHERCATEMGZ491.PNET Single-Channel Amplifier for PROFINET IOEMGZ492.ECAT Dual-Channel Amplifier for ETHERCATEMGZ492.PNET Dual Channel Amplifier for PROFINET IOEMGZ600 Series Digital Tension Measuring AmplifierExMGZ100/200.ATEX Intrinsically Safe Barrier for Zone 1F202 Force Measuring SensorFA202 Force Measuring Sensor with Dead Shaft AdapterFMS Force Sensors for explosive areasFMS-webDIRECTOR 041/042FMS-webMASTER 020FMS-webMASTER BKS 030 Web GuideFMS-webMASTER BKS015 EE Web Guide with External ElectronicFMS-webMASTER BKS015 Ultra-compact Web GuideFMS-winderGLIDE Type D.3 ActuatorFMS-winderGLIDE Type D.6 ActuatorHand PrinterIMGZ Series Force Measuring RollerJG205 Force Measuring JournalLMGZ Force Measuring BearingLMGZ.D Double Range Force Measuring BearingManual Sensor Adjustment BKS.VMotorized Sensor Adjustment BKS.TAPMGZ Force Measuring Bearing BlockRemote CounterRMGZ Force Measuring Rollers – Robust and preciseRMGZ100B Force Measuring RollerRMGZ200 Force Measuring RollerRMGZ300A Force Measuring RollerRMGZ400 / 600 Force Measuring RollerRMGZ800A Force Measuring RollerRMGZ900 Force Measuring RollerRMGZ900mini Force Measuring RollerRTM MP System: Bi-Directional, Radio-Based Signal Transmission for Rotating MachineryRTM X42 - System Overview Wireless Tension MonitoringRTM X42.BC Brake Control – System extension for continuous tension controlRTM X42.CC Control Center – System extension for visualization of tension dataRTM X42.MODBUS - Integrated Solution with Bus Interface to a PLCRTM X42.MODBUS/PC - Integrated Solution with Interface to PLC and PC/RTM-Software PackageSMGZ Force Measuring Bearing BlockUMGZ Force Measuring Bearing BlockUMGZ.P Force Measuring BlockUS01B/04B Series Ultrasonic Edge SensorZMGZ Force Measuring Journal