Ultrasonic Tension Controller for Web Tensioning

Abstract

The design of the Ultrasonic Tension Control package provides an industrial package to a previously vulnerable product. The previous design utilized a microcontroller which took analog feedback from an ultrasonic sensor to control brake pressure to a tensioning system to wind or unwind different products. The system still uses an ultrasonic sensor but uses a programmable logic controller (PLC) and variable frequency drive (VFD) to control the winding and unwinding speed. By using more industrial components, the system is more durable and resistant to shock, temperature, or other extreme environments. The introduction of a touch screen is also favorable and provides a convenient interface for operators to run the full process or troubleshooting to be done on a screen that puts the system into a manual mode. Future design considerations include putting the design into a smaller footprint for further cost reduction. Also the ability to automatically detect the type of variable frequency drive connected would be beneficial to prevent the user from incorrectly entering data.