Common Problems Associated With A Failing Web Tension Control System

In most applications using tension measurement systems, there is an expectation that the system will work effectively and provide accurate information and adjustment to the tension within the set parameters.

A quality web tension control system will be able to provide this level of precise control on any equipment and for any type of process. Choosing the most reliable system and the best manufacturer is always important, with cheap systems often requiring significant maintenance and offering limited viability, resulting in the need for a replacement of the system in just a few years. It is not uncommon for the quality systems to last for decades with extremely limited maintenance throughout their extended life cycle.

Signs of Problems

One of the most obvious issues with a poor-quality web tension control system is the lack of ability to accurately control the web. The system should be designed to provide the correct tension throughout, with the idler rolls and the driver rolls all being in traction with the web. In other words, the web has to have traction on the rolls, if it slides across the face of the rolls it cannot be guided and will wrinkle and twist.

Another common issue with an ineffective, poorly maintained or incorrectly installed web tension control system is excessive stretching. This occurs when some parts of the machine are under different tension, creating a stretching effect in parts of the system that impacts the quality of the web throughout the process.

The same types of issues can occur with unwinding as well. When tension is not uniformly controlled in the unwind application the rolls will telescope, and web breaks and wrinkling will occur.

Choosing a quality manufactured web tension system from a reputable manufacturer can eliminate these issues and increase the quality and performance of the process.

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