ABB PFTL201D 100KN 3BSE008922R0100 Tension Sensor



ABB PFTL201D 100KN 3BSE008922R0100 Tension Sensor

Product Overview

ABB PFTL201D (range 100KN, order number 3BSE008922R0100) is a high-precision tension detection equipment launched by ABB in the field of industrial measurement. It is designed for tension control scenarios in various industrial production processes and is widely used in industries such as metallurgy, papermaking, textiles, cable manufacturing, film production, and port lifting. This sensor is based on mature strain gauge measurement principles, combined with ABB's advanced signal processing technology and robust mechanical structure design. It can collect real-time and accurate tension data of the measured object, providing reliable basis for closed-loop control of the production process. It is the core sensing component to ensure stable operation of the production line and improve product quality.

As an important member of the ABB process instrument family, this tension sensor has wide range adaptability, strong environmental adaptability, and good compatibility. It can seamlessly integrate with various ABB control systems (such as AC800M, Freelance, etc.) and third-party PLCs to meet the personalized tension detection and control needs of different industries.

Core functions and technical features

2.1 Core detection function

-High precision tension acquisition: Using imported high-precision strain gauges and ABB dedicated signal conditioning chips, precise acquisition of tension signals within a range of 100KN is achieved. The measurement accuracy can reach ± 0.1% FS, and the linear error is less than 0.05% FS, ensuring stable and reliable tension data output under both dynamic and static working conditions, providing support for refined production control.

-Real time signal output: Supports multiple standard signal output modes, including 4-20mA analog signals, RS485 digital signals (Modbus RTU protocol), etc., which can be flexibly selected according to actual application scenarios to achieve real-time transmission of tension data, making it easy for the control system to quickly respond to tension changes.

-Tension state monitoring and feedback: equipped with tension over limit monitoring function. When the tension value exceeds the preset upper and lower limit thresholds, an alarm signal can be sent out through the built-in alarm module or communication interface to remind the operator to intervene in a timely manner, avoiding product damage or equipment failure caused by abnormal tension.

-Temperature compensation function: Built in multi-stage temperature compensation circuit, which can automatically correct the influence of temperature drift on measurement results within the ambient temperature range of -20 ℃ to 80 ℃, ensuring that measurement accuracy is not affected in complex temperature environments (such as metallurgical high-temperature rolling, cold storage material transportation, etc.).

2.2 Key Technical Features

-Durable and sturdy mechanical structure: Made of high-strength alloy steel material as the elastic body, it has undergone quenching and tempering heat treatment and precision mechanical processing, possessing excellent fatigue resistance and mechanical strength. It can withstand 150% FS overload impact without damage and adapt to harsh working conditions such as frequent start stop and load fluctuations in industrial sites. Its service life can reach over 100000 hours.

-Strong anti-interference performance: The circuit design adopts optoelectronic isolation, electromagnetic shielding, and surge suppression technology to effectively resist electromagnetic interference, voltage fluctuations, and radio frequency interference in industrial sites, ensuring stable output of tension signals without drift or distortion in environments with dense interference equipment such as frequency converters and motors.

-Convenient installation and calibration: adopting a modular structure design, equipped with various installation accessories such as flange and suspension, which can quickly adapt to different installation scenarios; Support on-site zero point calibration and range calibration. Operators can complete calibration operations through dedicated calibration tools or controllers without the need for professional technical personnel to provide on-site services.

-Complete self diagnostic function: Built in hardware fault diagnosis module, which can monitor sensor elastic strain abnormalities, signal conditioning circuit faults, power supply faults, etc. in real time. When a fault occurs, the fault information is fed back through the output of fixed fault signals or communication messages, making it easy to quickly locate and troubleshoot the problem.

Applicable scenarios and application advantages

3.1 Main Applicable Scenarios

This tension sensor has a precise range of 100KN and is widely used in various medium to large tension control scenarios, including:

-Metallurgical industry: Tension detection and control during the rolling process of steel strips, steel wires, and aluminum foils to ensure uniform material tension and improve product flatness and thickness consistency.

-Paper industry: Paper tension detection in the web, pressing, and winding sections of the paper machine to prevent paper breakage, wrinkles, and other issues during transportation, ensuring paper quality.

-Cable manufacturing: Tension control of conductors and insulation layers in the production process of cables and optical cables to avoid cable diameter deviation or wire breakage caused by uneven tension.

-Ports and Cranes: Rope tension detection for cranes and winches, real-time monitoring of load tension status to prevent overloading and ensure equipment safety.

-Film and Textile: Tension adjustment in the production process of plastic film and synthetic fabrics to ensure stable tension during stretching and winding, reducing product defects.

3.2 Application advantages

-Improving product quality: High precision tension detection and control can effectively avoid problems such as product size deviation and surface defects caused by tension fluctuations, significantly improving product qualification rate.

-Ensuring production safety: Real time tension over limit alarm and fault diagnosis function can provide early warning of equipment overload, material fracture and other risks, avoiding production accidents and reducing safety hazards.

-Reduce production costs: Stable tension control reduces material waste, high reliability design reduces equipment maintenance frequency and spare parts consumption, indirectly reducing enterprise production costs.

-Strong adaptability: Supports multiple signal output and installation methods, compatible with control systems of different brands, without the need for large-scale modifications to existing production lines, reducing upgrade costs.

Installation and maintenance precautions

4.1 Installation Requirements

-Before installation, it is necessary to confirm that the sensor range (100KN) matches the actual measured tension to avoid overloading; During the installation process, it should be ensured that the force axis of the sensor is consistent with the direction of the measured tension, to avoid additional forces such as lateral force and torque acting on the sensor, which may affect the measurement accuracy.

-The installation environment should avoid areas with high temperature, high humidity, strong corrosion, severe vibration, and dense dust. If it cannot be avoided, corresponding protective devices (such as heat shields, dust covers, shock absorbers, etc.) should be equipped.

-When wiring, it is necessary to strictly follow the pin definitions in the product manual to ensure stable power supply voltage (usually 24V DC). Signal cables should be shielded and laid separately from power cables to reduce electromagnetic interference.

4.2 Maintenance points

-Regularly (recommended monthly) inspect the appearance of sensors, clean surface dust and oil stains, check the tightness of installation accessories, and avoid measurement errors caused by looseness.

-Perform zero calibration on sensors once a quarter and comprehensive range calibration once a year to ensure measurement accuracy meets requirements; Calibration requires the use of standard force measuring equipment that has been certified by metrology.

-Avoid severe impact or collision on the sensor, and strictly prohibit hitting the elastic body of the sensor with hard objects; When the equipment is shut down for maintenance, the sensor power should be cut off first, and then relevant operations should be carried out.

-When the sensor experiences measurement data drift, no signal output, or abnormal alarm, it is necessary to promptly contact ABB's official after-sales personnel for maintenance, avoid disassembling the sensor on your own, and avoid damaging the internal structure.