Blog: Troubleshooting Tips Delivered to You in 2 Weeks or Less
Multiple Webs Over a Single Load Cell Roller?
Productivity is always a major point of emphasis, and one that has led some manufacturers to process multiple rolls of material through a machine (that was originally designed for one roll) at the same time. If multiple rolls of material can be processed side by side within a machine; to ensure high quality results, tension must be measured, and controlled on each roll separately. In applications like this, multiple webs of material should not pass over/utilize the same load cell roll.
If they do, accurate tension measurement and control, is often very difficult; potentially causing a tremendous amount of web tension related issues from inaccurate tension readings, poor controls, material quality issues, finished roll quality issues and a high level of scrap.
So why can’t multiple, separate rolls of material utilize the same load cells?
Outside of a specially designed segmented load sensing roller, a pair of load cells cannot be configured to independently measure multiple places on a roll and thus sends a singular measurement to the tension controller throughout the process. They simply don’t know if it’s one web or twenty webs.
If running multiple webs over the same load cell roll, the load cells are essentially measuring the AVERAGE tension of the multiple webs. The controller then uses this average to control the torque device (brake/clutch) and tension.
Montalvo Z4, X, DTI, and D tension controllers can be field configured for unwind, intermediate, or rewind control utilizing load cells, dancers or sensors depending on the configuration. If a tension controller is re-configured in the field its function won’t match its original product label which can sometimes lead to confusion or errors if the controller isn’t being utilized how it’s configured. In this case you will want to confirm what configuration your tension controller is in.
Tension Control Components Delivered in 2 Weeks or Less
Get the process improvements you require through our industry leading tension control products faster than ever. We are proud to offer some of the shortest lead times in the industry on controllers, load cells, safety chucks, amplifiers and more.
Available products in 2 weeks or less include:
S4 Tension Controllers
U4 Open Loop Tension Controllers
ES Dead Shaft-Idler Load Cells
CD Tension Brakes
DPS 45 Dancer Position Sensors
US4 100mm to 1m Ultrasonic Sensors
MPC4 IP Converters and PDA Valves
Additional Montalvo products are still available within 3 or 4 weeks, including Z4 Controllers, V, HP and Standard Brakes, Guardian Safety Chucks (standard), U Series Load Cells and much more. Half the time of other manufacturers.
Quality, performance, and productivity delivered quickly to you!