Views: 222 Author: Leah Publish Time: 2025-03-27 Origin: Site
Content Menu
● Introduction to Maxcess Tension Sensors
>> MAGPOWR TS Line of Web Tension Sensors
● Key Features of Maxcess Tension Sensors
● Applications of Maxcess Tension Sensors
>> Cygnus Tension Controller Features
● Spyder-Plus-S1 Tension Control
>> Spyder Plus Tension Controller Features
>> VERSATEC Tension Controller Features
>> 1. What are the primary applications of Maxcess tension sensors?
>> 2. How do Maxcess tension sensors enhance manufacturing efficiency?
>> 3. What is the significance of load cell calibration in Maxcess tension control systems?
>> 4. How does the Cygnus Tension Controller support multiple setups?
>> 5. What safety features do Maxcess tension control systems offer?
Maxcess tension sensors are integral components in various industrial applications, particularly in web processing and material handling. These sensors are designed to measure tension accurately, ensuring consistent quality and operational efficiency in manufacturing lines. In this article, we will delve into the key features of Maxcess tension sensors, exploring their specifications, applications, and how they enhance precision in manufacturing processes.
Maxcess, part of Maxcess International, offers a range of tension control solutions that have become the industry standard globally. With over 40 years of experience, Maxcess has developed a broad portfolio of products, including tension controls, readouts, load cells, brakes, and clutches. These products are designed to meet specific needs across various applications, from simple setups to complex systems.
The MAGPOWR TS line of web tension sensors is renowned for its accuracy in measuring tension in unwind, rewind, or intermediate web processing applications. These sensors are characterized by their robust specifications:
- Gage Resistance: 350 ohms
- Excitation Voltage: 10 VDC nominal
- Output Signal: 21 mVDC nominal per sensor at full load rating
- Operating Temperature: -30°C to 90°C
- Combined Non-Linearity and Hysteresis: 0.5% of full scale maximum
- Repeatability: 0.2% of full scale maximum
- Deflection at Full Load: 0.016 in. (0.41 mm) maximum
- Temperature Effect on Zero: 0.02% of rating per °C.
These specifications highlight the precision and reliability of Maxcess tension sensors in various environmental conditions.
1. Accuracy and Reliability: Maxcess tension sensors are designed to provide precise measurements, ensuring consistent product quality. Their robust construction and low temperature drift make them reliable in various environmental conditions.
2. Versatility: These sensors are adaptable to different applications, including paper, film, foil, tire and rubber, battery, metal, and wire processing. They can be integrated into existing systems, enhancing overall efficiency.
3. Advanced Technology: Maxcess utilizes advanced technologies such as load cells and ultrasonic sensors to measure tension and roll diameter accurately. This technology supports closed-loop control systems, maintaining constant tension even in demanding applications.
4. Ease of Installation and Maintenance: Maxcess tension sensors are designed for easy installation and maintenance. For example, the MAGPOWR tension sensing rollers can replace standard idler rollers, providing precise web tension measurement with minimal setup required.
5. Safety and Monitoring: Maxcess offers tension monitoring products that provide accurate readouts, helping prevent issues before they arise. Their systems also include safety features like web break detection and inverse diameter output to reduce equipment wear.
Maxcess tension sensors are used in a variety of applications:
- Web Processing: In unwind, rewind, and intermediate processing stages, these sensors ensure consistent tension, which is crucial for maintaining product quality and preventing material damage.
- Material Handling: They are used in systems handling different materials like paper, film, and metal, ensuring that the tension is optimized for each material type.
- Manufacturing Lines: Maxcess sensors are integral in maintaining efficiency and quality in manufacturing lines by providing real-time tension feedback, allowing for quick adjustments to maintain optimal production conditions.
Maxcess offers a range of tension control systems designed to optimize precision in manufacturing operations:
1. Closed-Loop Systems: These systems use feedback from load cells or other sensors to maintain constant tension, even in start/stop applications or with out-of-round rolls.
2. Dancer and Load Cell Systems: These are preferred for demanding applications, providing features like inverse diameter output and web break detection to ensure precise control and prolong equipment life.
3. Cygnus Tension Controller: This is a load cell-based tension control system that offers a user-friendly interface for monitoring and adjusting tension levels. It supports multiple setups and can display tension in digital or analog formats.
- Web Break Detection: Automatically detects web breaks to prevent material waste and equipment damage.
- Out-of-Round Roll Compensation: Adjusts tension to compensate for irregularities in roll shape, ensuring consistent product quality.
- Auto Tuning: Automatically adjusts system parameters for optimal performance, reducing setup time and improving consistency.
The Spyder-Plus-S1 is another advanced tension control system from Maxcess, designed for precision and ease of use. It requires load cell calibration to ensure accurate tension measurements. This system supports various operating modes, including closed-loop, open-loop, unwind, rewind, point-to-point, or dancer applications.
- Compact Design: Allows for easy installation in tight spaces.
- Ethernet Connection: Enables remote troubleshooting, programming, and data collection via a web browser.
- Analog Input: Supports manual level setpoint adjustments.
- Control Inputs: Includes Run/Stop, Auto/Manual, Tension On/Off, and E-Stop controls.
The VERSATEC Tension Controller is a multi-function automatic tension or process controller that uses the US-2 Ultrasonic Sensor to measure distance and roll diameter. It offers selectable operating modes for unwind, rewind, dancer, free loop, or ranging applications, making it versatile and efficient.
- US-2 Ultrasonic Sensor: Provides accurate measurements of roll diameter and distance.
- Multi-Line Alphanumeric Display: Offers clear and intuitive setup and operating screens.
- Setup Selection: Allows for storing up to four setups for quick changeovers, reducing downtime.
Maxcess also offers tension sensor amplifiers like the TSA model, which is designed to amplify the output signal from tension sensors. The TSA amplifier supports various input ranges and output formats, making it adaptable to different applications.
- Supply Voltage: 115/230 VAC, switch selectable.
- Sensor Excitation: 5 or 10 VDC.
- Output Options: 0 to 10 VDC or 4 to 20 mA DC.
Maxcess tension sensors are pivotal in ensuring precision and efficiency in various industrial applications. Their robust design, advanced technology, and versatility make them a preferred choice for tension control solutions worldwide. By integrating Maxcess tension sensors into manufacturing lines, companies can enhance product quality, reduce downtime, and improve overall operational efficiency.
Maxcess tension sensors are primarily used in web processing and material handling applications, including unwind, rewind, and intermediate stages. They are crucial for maintaining consistent tension in various materials like paper, film, and metal.
Maxcess tension sensors enhance manufacturing efficiency by providing precise tension measurements, allowing for real-time adjustments to maintain optimal production conditions. This reduces material waste, improves product quality, and minimizes downtime.
Load cell calibration is essential for ensuring accurate tension measurements in Maxcess systems. It involves setting the maximum tension and applied tension to scale the output correctly, ensuring that the system operates within the desired tension range.
The Cygnus Tension Controller supports multiple setups by allowing operators to pre-program settings for different materials or production conditions. This makes it easy to switch between setups without extensive reconfiguration.
Maxcess tension control systems offer safety features such as web break detection and inverse diameter output. These features help prevent equipment damage and ensure safe operation by maintaining constant tension and detecting potential issues before they occur.
[1] https://www.maxcessintl.com/wp-content/uploads/2021/07/MAGPOWR_Tension_Sensors_Manual_850A260.pdf
[2] https://www.maxcessintl.com/product/tension-controls/torque-controls/versatec-tension-control/
[3] https://www.maxcessintl.com/wp-content/uploads/2021/07/TSA_Manual_850A263.pdf
[4] https://www.maxcessintl.com/product/tension-controls/torque-controls/spyder-plus-tension-control/
[5] https://www.maxcessintl.com/product/tension-controls/torque-controls/cygnus-tension-control/
[6] https://www.maxcessintl.com/wp-content/uploads/2023/02/Tension-Control-Solutions-EN.pdf
[7] https://www.maxcessintl.com/products/tension-controls/
[8] https://www.maxcessintl.com/resources/tension-control-resources/
