Mitsubishi LE-40MTA-E Tension Controller for Web Processing Industries

Product Overview

The Mitsubishi LE-40MTA-E is a dedicated tension controller designed for web handling applications such as printing, laminating, coating, slitting, and converting. This controller maintains constant tension on materials like paper, film, foil, or fabric during unwinding, rewinding, and intermediate process sections. The LE-40MTA-E accepts input from tension sensors (load cells) or dancer rollers, compares the measured tension to a setpoint, and outputs a control signal (usually 0-10 V or 4-20 mA) to a drive or brake to adjust speed or torque. The result is consistent web tension regardless of roll diameter changes or speed variations.

Key Features of LE-40MTA-E

The LE-40MTA-E features a microprocessor-based PID control algorithm with auto-tuning capability for optimal performance. It includes a built-in 2-line LCD display (backlit) showing actual tension, setpoint, and diagnostic information. The controller provides analog inputs for one or two tension sensors (differential amplifier), and analog outputs for controlling a drive or pneumatic brake. It also includes digital inputs for start/stop, and relay outputs for alarm and run status.

The unit supports both open-loop (diameter calculation) and closed-loop tension control modes. It includes a taper tension function for winding applications, reducing tension progressively as the roll builds to prevent telescoping. The LE-40MTA-E operates from 100-240 V AC power and is housed in a DIN-rail mountable case. It includes screw terminals for all field connections. The controller can be configured via front-panel buttons or through a PC using optional software. It has a memory backup for parameters.

Technical Specifications

• Manufacturer: Mitsubishi Electric

• Part Number: LE-40MTA-E

• Product Type: Tension Controller

• Control Mode: PID closed-loop, open-loop with taper tension

• Sensor Inputs: 2 channels (load cell or dancer, 0-10 V or 0-20 mA)

• Analog Output: 0-10 V or 4-20 mA (programmable)

• Digital Inputs: 4 (24 V DC, e.g., start, stop, reset)

• Relay Outputs: 2 (alarm, run, 250 V AC, 2 A)

• Display: 2-line 16-character LCD with backlight

• Power Supply: 100-240 V AC ±10%, 50/60 Hz

• Power Consumption: 15 VA

• Control Algorithm: PID with auto-tune

• Taper Tension: Linear or curve programmable

• Mounting: DIN rail (35 mm) or panel mount

• Operating Temperature: 0 to +50 °C

• Storage Temperature: -20 to +70 °C

• Dimensions (W x H x D): 110 mm x 90 mm x 60 mm (approx.)

• Certifications: CE, RoHS

Functional Description

In operation, the LE-40MTA-E reads the tension signal from load cells mounted on the idler roll. The PID algorithm calculates the error between measured tension and setpoint, then outputs an analog signal to a brake or drive. For unwind stands, the controller typically commands a brake to hold back tension. For rewinds, it commands a drive to pull against a brake. The taper tension feature modifies the setpoint as roll diameter changes (calculated from line speed and speed reference). The controller can also accept a dancer arm position signal as input. Auto-tune mode automatically sets PID gains by performing a small disturbance and measuring the response.

Applications

The LE-40MTA-E is used in paper mills, plastic film extrusion lines, textile processing, label converting, and metal foil rolling. It is ideal as a replacement for older tension controllers or as an upgrade to improve product quality.