That tension indicator on your web processing machine might not seem too important when the machine is running well. However, when web breakages become more frequent and operators are adjusting dials to tease the machine into starting and stopping without causing web wrap-ups or sheet breakages then something is definitely amiss.
Loadcell failures may remain undetected for years. Even the total failure of one loadcell in a pair may not be picked up as the material may tolerate the higher tension being introduced as a result.
One customer of ours had suffered for many years with loadcell drift, requiring the machine to be regularly recalibrated. This was until they finally gave us the go-ahead to upgrade all of their loadcells with units from ABB.
Following installation and commissioning by Optima’s engineers, the results have exceeded their expectations. Productivity on the machine rose by 25%, with web breakouts now a distant memory. Senior management questioned why they hadn’t done this 5 years previously.
You see there is a difference between loadcells. Conventional units rely on strain gauges which can be broken by overload or misuse. What machine owner hasn’t experienced issues with incorrect use of their equipment by operators which can of course occur by accident or mistakes?
The ABB units we install as part of our web transport system upgrades or as a stand-alone improvement are truly a fit and forget solution. From versions that are acid resistant (for use on the wet end of paper machines) to radial and pillowblock types, there is a design and tension rating to suit any application.
The tension indicator units are robust enough to be mounted externally meaning engineers and operators can very easily check the tension reading from either or both loadcells during operation or maintenance. Factor in one-touch calibration and you can see why these units are our first choice.