1.Product Introduction
Applying on the payoff spooler, the tension controller could calculate the diameter of the spool in real-time, and adjust the controlled torque, keeping tension constant from full spool to empty.
It can solve problems of tension insufficiency and unstability, and reduce the resulting product quality defects.
2.Product Selection
| Normal Applications | Model | Normal Line speed | Increased Range of Tension |
| Passive low-tension control for stranding machines, tubular stranders, etc. | ZR1301-200 | 100m/min | +1 – 8Kg( Subject to actual on-site demands.) |
| Passive tension control for stranding machines, tubular stranders, etc. | ZR1301-500 | 100m/min | +3 – 20Kg( Subject to actual on-site demands.) |
| Passive tension control for higher tension conditions, like wire drawing machines, wire rewinding machines, heat treatment lines, galvanizing lines, etc. | ZR1301-750 | 100m/min | +5 – 30Kg(Subject to actual on-site demands.) |
3. Application Cases
3.1Core Wire/ Strand Tension Control on Double-Twisting Machine
| Model | Cord Specifications | Normal Line Speed | Pay-off Spool Model | Increased Range of Tension | Tension Fluctuation Range |
| ZR1301-500 | 1522/3833, etc. | 100 m/min | Type 120 (OD 1200, ID 500) | 5–8 kg | ±5% |
3.2Core Wire/ Strand on Tubular Strander
| Model | Cord Specifications | Normal Line Speed | Pay-off Spool Model | Increased Range of Tension | Tension Fluctuation Range |
| ZR1301-750 | 1+6+12/7×7, etc. | 40 m/min | Type 360 (OD 3500, ID 1500) | 10–25 kg | ±5% |
3.3Straight-line Wire Drawing Machine
| Model | Production Wire Specifications | Normal Line Speed | Pay-off Spool Model | Increased Range of Tension | Tension Fluctuation Range |
| ZR1301-750 | 2.0~4.0 mm | 180 m/min | Type 1000 (OD 1200, ID 500) | 20kg | ±5% |
3.4Wire Rewinding Machine
| Model | Production Wire Specifications | Normal Line Speed | Pay-off Spool Model | Increased Range of Tension | Tension Fluctuation Range |
| ZR1301-500 | 2.0~3.0 mm | 200 m/min | Type 1000 (OD 3100, ID 1250) | 5-10kg | ±5% |
3.5Creel Pay-off Unit
| Model | Production Wire Specifications | Normal Line Speed | Pay-off Spool Model | Increased Range of Tension | Tension Fluctuation Range |
| ZR1301-500 | 2.0~4.0 mm | 30 m/min | Type 120 (OD 1200, ID 500) | 5-10kg | ±5% |
3.6Strip pay-off Unit
| Model | Production Copper Strip Specifications | Normal Line Speed | Pay-off Spool Model | Increased Range of Tension | Tension Fluctuation Range |
| ZR1301-500 | 10 mm | 50 m/min | Type 570 (OD 1800, ID 800) | 5-10kg | ±5% |
3.7Galvanizing & Heat Treatment line
| Model | Production Wire Specification | Normal Line Speed | Pay-off Spool Model | Increased Range of Tension | Tension Fluctuation Range |
| ZR1301-750 | 2.0/2.5/3.0/4.0, etc. | 55 m/min | Type 1000 (OD 3000, ID 1250) | 15~30 kg | ±5% |
3.8Galvanizing & Heat Treatment line
| Model | Production Wire Specification | Normal Line Speed | Pay-off Spool Model | Increased Range of Tension | Tension Fluctuation Range |
| ZR1301-750 | 2.0/2.5/3.0/4.0, etc. | 55 m/min | Type 1000 (OD 3000, ID 1250) | 15~30 kg | ±5% |
| The advantages of tension control in the heat treatment line | Advantages | Specific Performance |
|
Before Retrofit (Mechnical Tension Control)
After Retrofit (Tension Controller) |
Dimensional Accuracy Control | Effectively prevents diameter shrinkage, ensuring diameter, length and out-of-roundness within standard limits. |
| Mechanical Property Assurance | Avoids uneven internal stress distribution and optimizes grain morphology and orientation. | |
| Real-time Compensation Capability | The unwinding circumference is calculated by collecting line speed and actuator rotational speed to realize real-time tension compensation. The tension remains within a reliable range throughout the whole production process from full spool to empty. | |
| Energy Saving & Environmental Protection | No external power drive is required, with almost no additional energy consumption under steady operating conditions. | |
| Low Maintenance Cost | No wearing friction parts are involved, featuring low maintenance workload and excellent long-term stability. |
