Magpowr | Tension and Torque Control Overview

A variety of advanced yet easy-to-use features are apparent immediately to operators using MAGPOWR’s compact, powerful Cygnus® Tension Controls. Operators can easily navigate through advanced tension control functions and codes using on-screen prompts displayed in full text, making the setup process faster. Web tension is maintained or adjusted using multifunction “smart keys,” similar to those used in ATMs, and a large backlit display for easy viewing. Converters and printers can dramatically reduce setup time and improve consistency with powerful features like automatic tuning and out of round roll compensation (previously only possible with a dancer control). Complex tension settings can be input quickly with full text prompts as opposed to more complicated input procedures of the past.

MAGPOWR’s VERSATEC Versatile Tension Control provides true ease of use and extreme flexibility with its wide range of functions and operating modes. The VERSATEC Versatile Tension Control is a multi-function automatic tension or process controller that uses the US-2 Ultrasonic Sensor to measure distance and roll diameter. It has selectable operating modes for Unwind, Rewind, Dancer, Free Loop, or Ranging applications. This flexibility eliminates the need to learn the operation of different controls for different tension zones. All setup and operating screens on the VERSATEC unit are indicated directly on the multi-line alphanumeric menu driven display in real words, not codes, with the corresponding values or status. From the keypad and display, you can control all operating parameters for any operating mode, including tension, distance, dancer position, loop position, alarm set points, security, language and units, and setup selection.

Designed for precise tension control, MAGPOWR’s cost-effective Spyder Tension Control is capable of controlling web tension in closed-loop, open-loop, unwind, rewind, point-to-point or dancer applications. It measures tension from one or more MAGPOWR load cells and outputs a corrective analog signal to control a torque device. Its reduced size means it can be hidden away in an enclosure or underneath the machine. With its Ethernet connection, the easy-to-use Spyder can be viewed on a web browser for remote troubleshooting, programming and/or data collection. Additionally, the Spyder provides an analog input for Manual Level setpoint, control inputs for Run/Stop, Auto/Manual: Tension On/Off, and E-Stop, and a 0-1 mADC meter output proportional to measured tension. Spyder Plus has the ability to control open loop applications, advanced features for dancer applications, and the ability to interface and share data remotely. Spyder Plus now has powerful features for dancer applications that were once only available with more expensive controls. Dancer mode now allows the unique ability to use load cells to monitor web tension, while remote setpoint adjustment improves efficiency, especially when multiple controls are used in the same application. Spyder Plus also works with third party ultrasonic or laser sensors to determine roll diameter.

Need control of a dancer, follower arm or both? No problem, as MAGPOWR’s DFC-90 and DFC-A low-cost tension controls can handle either operation mode. Dancer Mode: The DFC-90 and DFC-A are full PID closed-loop dancer controls, controlling web tension by sensing the position of the dancer arm through a DFP or DFP-2 Position Sensor and adjusting the clutch, brake or motor control torque accordingly to maintain the dancer position set point. Follower Arm Mode: The DFC-90 and DFC-A control web tension by compensating for measured changes in the roll diameter. Roll diameter changes are measured through the DFP or DFP-2 Position Sensor and a follower arm. An optional Stop Multiplier provides additional stopping torque to help stop large unwind rolls.

Dependable current-regulated power supplies are imperative for the proper operation of all magnetic particle clutches and brakes, and MAGPOWR’s are no different. The MAGPOWR TC-5 is a solid state current regulated 90 VDC power supply. It has four current ranges of 1/8, 1/4, 1/2 and 1 amp, selected by a simple jumper on the circuit board. This unit also includes reverse current circuitry as a standard feature, thus allowing greater controllability in the lowest torque range of the clutch or brake being operated. The TC-5 is easy to work with, as the front panel meter indicates the current output and automatically reads full scale for each current range selected. The operator controls the output by rotating the front panel potentiometer.

Complete control is the goal of any operation utilizing brakes and clutches. MAGPOWR’s PS-24 & PS-90 Power Supplies provide a small amount of reverse current circuitry as a standard feature to minimize the drag torque of a clutch/brake, allowing greater controllability in the lowest torque range. These power supply units control any size MAGPOWR clutch or brake with optimum resolution. MAGPOWR’s current-regulated power supplies are used for the control of magnetic particle clutches and brakes in unwind, rewind, or intermediate tension control applications. With selectable current ranges, these compact enclosures can be mounted inside the machine cabinet, allowing your operator to adjust torque through a remotely mounted potentiometer or with a 0 to 10 vdc control signal from MAGPOWR Open Loop and Closed Loop controllers, or any control device like a computer or PLC.