Tension Control Systems
Warner Electric tension control systems, available from BIBUS Kft., provide complete solutions for the continuous and accurate tension control of web materials such as films, paper, textiles, cables and other roll-fed products. The systems combine electromagnetic tension brakes, analogue or digital controllers and various feedback technologies to maintain consistent web tension throughout the production process.
Warner Electric systems offer controllable braking torque from 0.5 Nm to more than 1,000 Nm, maintaining constant web tension even with roll diameter changes of up to 10:1. With both analogue and digital control options, the systems cover applications ranging from simple manual adjustment to highly accurate closed-loop tension control.
Warner Electric tension control systems are ideal for winding and unwinding machines, printing presses, film converting equipment, labelling machines and other continuous web handling applications where stable web tension directly influences product quality, production efficiency and process reliability.
Tension Brakes
Warner Electric electromagnetic tension brakes are designed for applications with different performance requirements. Their continuously adjustable braking torque maintains constant web tension even as the roll diameter changes during operation.
TB Series – Basic Tension Brakes
The TB Series is a compact electromagnetic tension brake designed for light and medium-duty applications.
Key Features
- 24 V DC operation
- Torque range: 0.7–347 Nm
- Compact design
- Outside diameter: 1.7"–15.25"
ATT Series – Advanced Technology Tension Brakes
The ATT Series provides increased accuracy and improved tension stability for demanding winding applications.
Key Features
- Rotating support mounting design
- Torque range: 10–84 Nm
MTB Series – Modular Tension Brakes
The MTB Series features a modular design that can easily be configured for high-performance applications.
Key Features
- Modular construction
- Outside diameter: 10"–20"
- Maximum torque: approximately 1,010 Nm
- Replaceable friction pads
- Up to 6 HP thermal capacity
Controllers
Warner Electric controllers provide precise control of the tension brakes to maintain constant web tension throughout the production process.
TCS-220
Analogue tension controller with integrated PID control.
Key Features
- 48 V DC
- Running current: 0–270 mA
- Braking current: 270–500 mA
- External potentiometer or analogue signal input
- Integrated PID control
MCS-203 & MCS-204
Modular controllers for smaller systems.
MCS-204
- Manual or analogue control
- 24 V DC operation
MCS-203
- Automatic dancer control
- Controls one or two brakes
XCTRL + X2DRV
Warner Electric's digital tension control platform.
Key Features
- Closed-loop control
- Dancer arm feedback
- Load-cell feedback
- High control accuracy
- Stable web tension throughout the entire winding process
System Advantages
✔ Constant web tension throughout the winding process
✔ Low hysteresis
✔ Accurate PID control
✔ Analogue and digital control options
✔ Dancer arm or load-cell feedback
✔ Handles roll diameter ratios of up to 10:1
✔ Supports flying splice operations
✔ Easy installation
✔ Low maintenance requirements
✔ Long service life
Typical Applications
✔ Winding machines
✔ Unwinding systems
✔ Printing presses
✔ Film converting machinery
✔ Labelling equipment
✔ Paper processing machines
✔ Textile machinery
✔ Cable manufacturing
✔ Battery foil production
✔ Continuous web handling systems
Why Choose Warner Electric Tension Control Systems?
✔ Complete system including brakes and controllers
✔ Analogue and digital control solutions
✔ Open-loop and closed-loop operation
✔ Accurate and stable web tension control
✔ Braking torque exceeding 1,000 Nm
✔ Plug-and-play installation
✔ Easy maintenance
✔ Engineering support from BIBUS Kft.
What Problems Do Tension Control Systems Solve?
✔ Maintaining constant web tension despite changing roll diameters
✔ Preventing film, paper and web breaks
✔ Reducing wrinkles and material deformation
✔ Improving winding quality
✔ Ensuring stable operation of high-speed production lines
✔ Reliable control during flying splice operations
How Can We Help?
The engineers at BIBUS Kft. help you select the most suitable Warner Electric tension control system, size the brakes and controllers, and determine the optimal control solution for your application.
