Strain gauge technology or piezoelectric crystal technology is used to accurately detect tiny tension changes (resolution can reach 0.1N or higher), support high-frequency sampling (such as above 1kHz), ensure real-time feedback, and have a built-in temperature sensor to automatically correct temperature drift to ensure stable operation in environments ranging from -20℃ to +80℃. The built-in tension control algorithm supports direct tension control (DTC) or indirect tension control (through speed/torque adjustment), and cooperates with external force sensors (such as pillow sensors) to maintain stable web tension through closed-loop control.

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　　PFCL201CE 10KN 3BSX105983-100 Other recommended names:

　　PFCL201CE 10KN 3BSX105983-100 Tension Sensor

　　PFCL201CE 10KN 3BSX105983-100 Load Cell

　　PFCL201CE 10KN 3BSX105983-100 Vertical Weighing Measurement Module

　　The PFCL201CE 10KN 3BSX105983-100 pillow-type tension sensor is a core component in ABB's industrial automation product line specifically designed for dynamic or static tension measurement. Its pillow-type (or "pillow block") design enables it to be embedded in tension control systems for web handling, textile, printing, packaging, and other equipment. By monitoring the real-time tension changes of materials (such as paper, film, metal strip, and fabric) during operation, the sensor converts the force signal into an electrical signal, which is fed back to the control system for precise adjustment, ensuring production process stability and product quality.

　　Core Features

　　Definition and Principle

　　The PFCL201CE 10KN 3BSX105983-100 Pillow Block Tension Sensor indirectly calculates tension by measuring the radial force exerted by a web (such as paper, film, or metal strip) on a support roller during operation.
       Its core structure is as follows:

　　Support roller: Serves as the web's load-bearing surface and is mounted on a bearing housing.

　　Force sensor: Integrated within or beneath the support roller, it detects the radial pressure exerted by the web on the roller.

　　Signal processing unit: Converts the pressure signal into a tension value (unit: N or kgf).

　　High-Precision Measurement:

　　Using strain gauge or piezoelectric crystal technology, it accurately detects even minute tension changes (with a resolution of 0.1 N or higher).

　　Compliant with international standards (such as OIML R60 and ASTM E4), it typically achieves an accuracy grade of C3 or higher.

　　Excellent Dynamic Response:

　　Designed for high-speed web handling, it offers a fast response time (in milliseconds) and adapts to dynamic tension fluctuations.

　　Supports high-frequency sampling (e.g., above 1kHz) to ensure real-time feedback.

　　Strong Environmental Adaptability:

　　Fully Sealed Structure: IP67 or IP68 rated for dustproof, waterproof, and corrosion-resistant.

　　Temperature Compensation: A built-in temperature sensor automatically corrects for temperature drift, ensuring stable operation in environments ranging from -20°C to +80°C.

　　Anti-Interference Design: Shielded cable and electromagnetic compatibility (EMC) design reduce signal interference in industrial environments.

　　Easy Installation:

　　The pillow-style design (cylindrical or square block) allows for easy integration into guide rollers, pressure rollers, or tension arms without complex mechanical modifications.

　　Supports lateral or vertical mounting to accommodate various equipment layouts.

　　Flexible Signal Output:

　　Analog signals: 4-20mA, 0-10V, ±5V, etc., compatible with traditional PLC systems.

　　Digital Signals: RS485, CANopen, EtherCAT, etc., supporting industrial Ethernet communication for easy integration into smart factories.

　　ABB's Tension Control Technologies

　　ACS880 Drive Series

　　Function: Built-in tension control algorithm, supporting direct tension control (DTC) or indirect tension control (via speed/torque regulation).

　　Application: In conjunction with external force sensors (such as pillow-type load cells), maintains stable web tension through closed-loop control.

　　ABB Ability™ Sensors and Measurement Systems

　　Force Sensor Options:

　　ABB Measurement & Analytics offers high-precision force sensors (such as pressure transmitters) that can be integrated into pillow-type structures.

　　Example Product: 266 Series Pressure Transmitters, suitable for force measurement in industrial environments.

　　Wireless Sensor Networks: Enable remote monitoring and data analysis with ABB Ability™ EdgeInsight.

　　DriveSync Synchronous Control System

　　Multi-axis Collaboration: DriveSync synchronizes multiple motors in equipment such as rewinders and slitters, indirectly controlling tension distribution.

　　Advantages of ABB's Solutions

　　High Precision and Stability

　　ABB's sensor and drive technology delivers millisecond-level response speeds, adapting to dynamic tension changes on high-speed production lines.

　　Integrated Design

　　Deep integration between the drive and tension control algorithm reduces external device complexity.

　　Support for industrial protocols such as Modbus and Profibus facilitates integration with PLC or HMI systems.

　　Energy Saving and Efficiency Optimization

　　ABB's Direct Torque Control (DTC) technology reduces motor energy consumption while improving tension control accuracy.

　　Typical Application Scenarios

　　Web Handling Industry:

　　Printing Presses: Monitor the tension of paper or film to prevent stretching, deformation, or wrinkles.

　　Rewinders: Control the winding tension of metal strips and plastic films to ensure a tight and uniform web.

　　Slitter: Maintain constant tension during the slitting process to prevent strip breakage and dimensional deviation.

　　Textile Industry:

　　Looms: Monitor the tension of warp and weft yarns to optimize fabric density and quality.

　　Dyeing and finishing equipment: Controls fabric tension during the dyeing and drying processes to prevent shrinkage and deformation.

　　Packaging industry:

　　Stretch wrapping machines: Adjust the tension of packaging film to ensure goods are wrapped tightly and without damage.

　　Bag making machines: Control film tension to ensure a smooth bag opening and strong seal.

　　New energy industry:

　　Lithium battery production: Monitors tension during electrode coating and rolling to prevent electrode breakage and uneven thickness.

　　Photovoltaic panel manufacturing: Controls the tension of backsheets and EVA films to ensure lamination quality.

　　Maintenance and troubleshooting

　　Regular calibration: Calibration every 6-12 months is recommended to ensure long-term accuracy.

　　Cleaning and maintenance: Wipe the sensor surface with a dry cloth to avoid oil and dust accumulation.

　　Common faults:

　　Signal drift: Check the temperature compensation function or replace any aging strain gauges.

　　No output: Check the power supply voltage, signal cable connections, or sensor for damage.

　　Slow response: Clean the guide roller surface or check the mechanical transmission for sticking.

　　Industry Trends and ABB Innovations

　　Intelligent Upgrade: ABB's latest generation of tension sensors integrates IoT functionality, supporting remote monitoring and predictive maintenance.

　　Multi-parameter Measurement: Some models can simultaneously monitor tension, speed, and position, simplifying system integration.

　　Energy-Efficient Design: Low-power circuitry and efficient power management make it suitable for battery-powered mobile devices.

　　Summary

　　ABB's pillow-type tension sensor PFCL201CE 10KN 3BSX105983-100, with its high accuracy, reliability, and flexibility, has become a preferred solution for industries such as web handling, textiles, and packaging. Proper selection and installation can significantly improve production efficiency and product quality while reducing maintenance costs.

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