What are the daily maintenance and operating precautions for tension controllers?

A tension controller is a control system that provides constant tension to winding or feeding rollers. It is widely applied in the winding and unwinding process of continuous coiled materials such as paper, films, wires and metal strips to support high-speed, high-performance production lines.

Tension Controller

Today we will mainly discuss the daily maintenance and operating precautions for tension controllers.

1. Daily Inspection

Clean the tension detection roller to remove adhesive, dust and thread scraps;

Check whether the tension display of the controller is stable and if there are any alarms;

Monitor the temperature rise of the magnetic powder brake; shut down the machine for cooling in case of overheating.

2. Monthly Maintenance

Carry out zero calibration for the sensor;

Tighten all wiring terminals and inspect shielding grounding;

Replenish magnetic powder when magnetic powder torque becomes insufficient;

Clean the filter screen of the cooling fan inside the electric control cabinet.

3. Environmental Protection

Take dust-proof and adhesion-proof measures in film and adhesive workshops to prevent sensor jamming;

Shielded signal wires must be used near frequency converters and servo motors, with grounding resistance less than 4Ω;

Waterproof controllers or sensors shall be adopted in humid environments.

4. Selection Guidelines

For thin materials and high-speed production lines: fully automatic closed-loop controller;

For low-speed adhesive tape and simple rewinding: semi-automatic roll diameter controller;

For small low-speed bag making machines: manual controller;

Magnetic powder matching: the standard output current of the controller is 0–4A. Amplifier drive modules are required for high-power magnetic powder units.