Roll Diameter and Tension Control

Maintaining the correct level of tension on web materials is significant to ensuring quality and appearance and to minimizing material breakage, wandering and other process issues that can lead to downtime. Measuring roll diameter and monitoring loop tension is fundamental to maintaining the correct amount of web tension. Variations in materials, as well as material color, translucence and reflectivity, even environmental conditions can challenge a sensor’s ability to detect and measure these targets. Banner offers sensors a in a range of sensing technologies capable of accurately and consistently measuring roll diameter and monitoring the tension of loops to ensure the correct level of web tension.

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  1. Roll Monitoring with a Laser Sensor

    The L-GAGE LT7 is aimed at a roll of print paper, constantly monitoring its diameter, to gauge the rate at which the printer is taking up the paper.

  2. Plastic Roll Diameter Measurement

    Banner’s LE550 is factory configured with a range of 100 to 1000 mm and can start measuring immediately. If the range needs to be adjusted, the laser sensor has an intuitive user interface with a two-line, eight-character display, making it easy to automatically or manually adjust settings. The LE550 provides repeatability and accuracy across challenging targets, from metal to black rubber, allows for reliable measurement of the shrink wrap.

  3. Laser Sensors Measure Paper Rolls in a Range of Colors & Automatically Scale Output

    After a convincing demonstration, the company chose Banner’s L-GAGE® LE550 laser gauging sensors to replace the ultrasonic sensors on their winders. Like the optical sensors, the LE550 is unaffected by drafts in the facility. Unlike the optical sensors, the LE550 is color insensitive. Linear array technology enables the LE550 to measure each roll, regardless of paper color, even colors that had most challenged the optical sensors.

  4. Roll Diameter Measurement of Dark Material

    Banner’s LE550 is factory configured with a range of 100 to 1000 mm and can start measuring immediately. If the range needs to be adjusted, the laser sensor has an intuitive user interface with a two-line, eight-character display, making it easy to automatically or manually adjust settings. The LE550 provides repeatability and accuracy across challenging targets, from metal to black rubber, allowing for reliable measurement of the dark blue material.

  5. Sheet Metal Roll Diameter

    Banner’s LE550 provides repeatability and accuracy across challenging targets, including shiny, reflective surfaces like metal. The laser sensor has an intuitive user interface, making it easy to adjust settings and set up a roll diameter application, without needing to unwind the metal roll. The analog output can be used to control wind or unwind speeds.

  6. Tension Loop Control for Clear Plastic

    In this application, monitoring of the tension loop control is done by an ultrasonic sensor, the Banner S18U. The S18U bounces sound waves off of the clear plastic for a reliable and consistent sensing application. Standard photoelectric sensors have difficultly detecting clear material, particularly if its condition changes – in this application, the loop will fluctuate.As the loop fluctuates, its distance from the S18U also changes.

  7. Vertical Form Fill Seal Machine Solutions

    Ultrasonic Sensor: Banner’s T30UX ultrasonic sensor delivers accurate distance sensing to provide a non-contact method to measure the roll of film’s diameter. By determining the roll’s radius, the vertical form fill seal machine can calculate the amount of film that remains and can signal the operator when it is low. The material should be advancing a predetermined distance equal to the desired length of each bag or package.

  8. Loop Control for Clear Plastic

    The analog U-GAGE S18U ultrasonic sensor positioned below a web of clear plastic monitors the tension of the loop, signaling the rate of uptake to increase or decrease as needed.

  9. Loop Control of a Web

    The D10 Expert detects the web if it droops into the sensor's beam because the tension is too loose; the D10 then sends a signal to the controller to adjust the speed accordingly.

  10. Loop Control of Clear Plastic

    The detection of clear plastic is always a challenge. The optical beam of traditional photoelectric sensors will burn through clear material, making sensing results unreliable. The U-GAGE T30UX Series Ultrasonic Sensor uses pulses of ultrasonic energy, which reflect off the target and back to the sensor, to reliably detect clear materials. In this application, a T30UX with an analog output is being used to monitor the tension of the loop.

  11. Clear Material Loop Control

    Banner’s T30UX ultrasonic sensor is the perfect sensor for detecting clear material for loop control because it uses sound rather than light, which makes it more accurate and cost-effective for this specific application. Although the material is clear, it presents a solid surface for an ultrasonic sensor to bounce a sound wave. The T30UX has a more accurate transducer, a smaller dead zone and minimum distance compared to other sensors that can be used for clear material detection.

  12. Roll Diameter on Labels

    In the beverage industry, labels need to be applied to the bottles quickly and without error to keep production levels high. Accurately monitoring the thickness on a spool of labels and controlling the unwinding speed is very important for the process to run smoothly. A solution is needed that can accurately supervise and report the material levels on a spool in order to prevent it from running out during the manufacturing process and delaying production.