ISO 9001 Certified ISO 9001 Certified DOVER FLEXO ELECTRONICS PRODUCT GUIDE Tension Innovation for Industry since 1974 Dover Flexo Electronics (DFE) manufactures and services a full line of tension measurement and control products for wide and narrow web. We are the leader in developing and supporting web tension control products and technology.
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9001
ISO 9001 Certified
ISO 9001 Certified
DOVER FLEXO ELECTRONICSP R O D U C T G U I D E
Tension Innovation for Industry since 1974
Dover Flexo Electronics
(DFE) manufactures
and services a full line
of tension measurement
and control products
for wide and narrow
web. We are the leader
in developing and
supporting web tension
control products
and technology.
Dover Flexo Electronics (DFE) manufactures and services a full line of tension measurement and control products for materials processing industries. We are a leader in developing closed-loop web tension control products & technology.
DFE serves manufacturers in converting, fl exible packaging, paper, foil, tag & label, wire & cable, extruded products, business forms, commercial printing, food processing and the OEMs serving those industries. Any continuous manufacturing process that involves web, ribbon or fi lament can benefi t from DFE’s application experience and broad assortment of product solutions.
Since 1974 DFE has been the natural choice for upgrading existing machinery with modern, effi cient tension control. Improvements in productivity and lower operating costs due to reductions in material waste can pay for the investment in a tension control system in as little as a few weeks. OEMs and machinery builders also choose DFE to incorporate the most reliable, easy-to-use tension devices into their equipment.
Our product categories include:» Tension Transducers» Tension Indicators» Automatic Tension Controllers » Pneumatic Tension Brakes» Custom Engineered Products and Systems
If you don’t fi nd what you need in this product guide, please contact us. Our skilled application engineers are ready to assist you in identifying the critical areas of your process. They can then recommend equipment– standard, modifi ed or custom engineered– that will fi t your budget and solve your tension problems. Ask for a free application analysis.
With over 100 years of combined experience in delivering control solutions for web presses and machines, our dedicated technical staff can even help you integrate DFE tension control products with auxiliary equipment from other vendors, including drives and/or clutches. Let us put our applications experience to work for you.
If you’re looking for a single tension control source that delivers the best value available anywhere, then you’ll fi nd what you need at DFE.
Global Offices...................................... 13
Typical Running Tensions of Common Web Materials
Contents
DFE’s Tension-Free 5 Year WarrantyDover Flexo Electronics, Inc. warrants its’ products to be free of defects in material and workmanship for 5 years from date of original shipment.
During the warranty period the Company will repair or replace defective products free of charge if such products are returned with all shipping charges prepaid and if, upon examination, the product is shown to be defective. This warranty shall not apply to products damaged by abuse, neglect, accident, modifi cation, alteration or mis-use.
For a copy of the full warranty, please contact DFE or visit www.dfe.com.
We honor:
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The Dover Difference
Dover Flexo is the value and innovation leader in the industries we serve. We strive to deliver superior product to you at a reasonable price with an emphasis on quality, reliability and unmatched technical support.
Dover Delivers• Leadership in product innovation, reliability
and custom tension measurement solutions since 1974
• 5 Year Product Warranty
• ISO 9001 Quality Assurance
• 24/7 Technical Support
• Superior, hassle-free customer service
• R&D Technical Support Center (Ask for a demo on the test machine.)
• All products designed and made in the USA
• Credit card acceptance
• Online resources at www.dfe.com
Dover Flexo Electronics and its Management have committed to
establishing and maintaining a formal and continual program of
evaluation, review and modifi cation of all of our operations so that the
Company’s ability to provide the highest quality products and
related services to our customers can be verifi ed and improved.
Tell us what you value, and we’ll deliver.
ISO 9001 Certified
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INTERMEDIATE ZONEINTERMEDIATE ZONEINTERMEDIATE ZONEUNWIND ZONEUNWIND ZONEUNWIND ZONE REWIND ZONEREWIND ZONEREWIND ZONE
Tension control is often used in manufacturing or printing sub-processes such as unwinding, winding, extruding, slitting, sheeting, coating, laminating, braiding, embossing and embedding. These operations can be highly involved. Proper web tension is needed for high-quality output. So it is important to work with a tension control supplier you can rely on– one with a range of reliable products, industry experience and excellent support capabilities.
Dover’s tension control products are designed to be integrated smoothly into your machine’s structure wherever your application demands them– the unwind zone, rewind zone, intermediate zone, or any combination of these. Reliable, durable, easy-to-install components that are also simple to use are the hallmark of a complete DFE tension control system.
Dover’s application specialists will custom-tailor a tension control package to suit your exact needs. Working together on your machinery, tension transducers, controllers, indicators, brakes, clutches and drives result in a level of process control previously unattainable. With an automated control system you will no longer need to monitor continuously and re-adjust tension throughout your operation. Dover controls do it all for you. This saves you manpower, cuts downtime, and improves the consistency and quality of your fi nished product.
The following sections highlight major features and benefi ts of each of our standard products. Please inquire if there does not appear to be a product to fi t your application. DFE delivers tension solutions for almost any continuous process machine.
Available Outputs for Tension Controllers
A range of brakes and torque capacity for light to heavy-duty
applications.
The broadest range of tension amplifier boards and indicators on the market.
Rugged, accurate transducers for use in almost any processing environment.
Versatility and ease-of-use are hallmarks of DFE controllers.
Tension Transducers
Amplifiers & Indicators
Tension Controllers
Pneumatic Brakes
D 0-10 VDC compensated output for use with adjustable speed DC and AC drives. The output is electrically isolated for compatibility and reliability. Used in all tension zones; unwind, rewind and intermediate.
V 0-90 VDC output. For usein all types of electrical brakes and clutches, including eddy current clutches. Also available with 24 and 45 VDC output. Commonly used in the unwind or rewind zones.
P 0-75 psi output for use with pneumatic clutches and brakes. Most commonly used in the unwind and rewind zones. System includes internal air filter and regulator (80-120 psi input pressure).
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Model TR
Model RS Based on the Model C transducer. A Roll Shell Transducer locks into the inner diameter at each end of an aluminum or steel tube to create a simple-to-install tension-sensing roll. Special expanding connector collet allows easy insertion of transducer into roll. Once tightened, the collet fastens the transducer fi rmly into the tube. Load ratings from 10-800 lbs. (44N-3559N; 4.5-364Kg)
Roll Shell Transducers
Specially designed transducer combines a cantilevered idler roll and two tension transducers in one unit—for fast, easy installation and high accuracy. Construction provides strength, corrosion-resistance and positive overload protection. Three widths accommodate narrow webs up to 14” (356mm) wide. Choose a single-bolt mounting or four-bolt fl ange.
Tension TransducersDover tension transducers measure actual web tension in almost any moving web or fi lament. Transducers output an accurate signal to an amplifi er, indicator or controller. All DFE transducers have rugged stainless steel and aluminum construction for reliability and corrosion resistance.
If you don’t see a transducer that fi ts your needs exactly, please call or e-mail us. We manufacture custom transducers to fi t almost any tension measurement application.
Items shown with the CE mark have been tested and have met the requirements of the Low Voltage Directive (73/23/EEC) and the EMC Directive (89/336/EEC) established by the member states of the European Union.
The industry standard in tension transducers. Completely sealed to protect inside from dust and water. Recessed seals are protected from damage. Available in three frame sizes and both live-shaft and dead-shaft
versions. Choose from fi ve mounting styles: screw, fl ange, pillow-block, thru-frame and piloted fl ange. Ask for the data sheet on these rugged, time-proven transducers.
General Purpose Transducers
Tension Roll® Tension transducers and dead-shaft idler roll are combined in one integral unit. No assembly required. Faster, easier, and less expensive to install than separate roll and transducers. Only one transducer cable-eliminates cable crossing between machine frames. Roll diameters from 3 inches (100mm) and up. Face widths to 120 inches (3050mm). Load ratings from 12 to 400 pounds (55 to 1800N; 5.4 to 182 Kg).
Model C
» Converts a simple metal tube into a tension-sensing idler roll
» Simple to install- Unit clamps into tube
» No shaft needed
» Accommodates axial thermal expansion up to 1/4” (0.64cm) in hot environments
» Two frame sizes
Model NWI
» For narrow web machines with single-side frame
» Transducers and idler roll combined into one unit
» Load ratings from 12–100 lbs. (55–450N; 25–45 Kg) with wide operating range
» Optional indicator on roll end
Narrow Web Transducers
» Transducers and idler roll in one, easy-to-install unit
» Fast, hassle-free installation-like any dead-shaft idler roll
» Aluminum, steel or stainless steel rolls in many surface finishes
» One electrical cable
» Dead shaft and live shaft models
» Five mounting styles
» Dual cantilevered sensing-beam for high accuracy
» Load ratings from 10-800 lbs (45-3560N; 4.5-364 Kg)
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Model UPBH and SUPB UPBH transducers are used in applications with the tension force direction parallel to the top plate. SUPB transducers are for use in applications with the main force component perpendicular to the transducer top plate. Designed for paper
processing applications, these transducers are built to last. Unique parallelogram construction provides strength and reliability. Made of corrosion-resistant stainless steel and aluminum. No hinges, no joints. Two frame sizes.
Heavy-Duty Tension Transducers
The VNW (Very Narrow Web) transducer measures process tension in narrow web (up to six inches wide), ribbon or fi lament. It mounts cantilevered on process machinery for unwind/payoff, rewind/take-up, or intermediate zone applications.
Very Narrow Web Transducer
Model RFA Designed to measure tension in any moving ribbon or fi lament. Ideal for ribbons or fi laments of wire,
plastic, rubber, metal, glass, composite or other materials. Three standard wheels available—for ribbon, for fi lament, or
adapter model for custom requirements. Three mounting styles available: “S”, “FL”, and “PB”.
Wire, Cable or Ribbon Transducers
Model THN THN is the thin (2.3 inch width) transducer of choice when a standard shaft-end transducer is too wide. A single-bolt mounting allows the THN transducer to be rotated to any position and oriented on the machine frame prior to idler roll installation. The removable clamp on the transducer’s shaft coupling allows the idler roll to be installed and removed without disturbing the transducers.
» 10VDC and 4-20mA isolated outputs proportionalto tension
» QuickCal™ push-button zero and calibration
»
» Choice of mounting styles, including DIN railmounting
FireGuard™ An intrinsically safe interface between transducers and a tension controller, drive system or computer. The UL listed FireGuard™ reduces risk of fi re or explosion in plant environments where combustible vapor may be present. Used when tension transducers and analog tension meter (optional) are located in a hazardous Class I Division 1 or 2 area. Can be used with drive systems, computers, PLC’s or DFE controllers. Outputs include 0 to+10V undamped isolated, and a 0 to 1 mA damped meter output.
Intrinsically Safe Indicator/ Amplifier
MAC The MAC Card is an eight-channel amplifi er/interface consisting of eight independent tension amplifi ers on a single circuit card.
The MAC provides excitation voltage to connected tension transducer pairs, and puts out a 0-to-10VDC signal proportional to tension for each pair of transducer signal inputs. The 0-to-10V outputs can be used as inputs to drives, PLC’s or other tension monitoring or closed-loop tension control devices. The 5.5 x 7 inch MAC Card installs fl at in the machine’s control panel.
MultiAmplifier Card for Tension Indication
iAmp™ Simplify web tension measurement with transducer-mount or cable-connect iAmp™ amplifi er modules. These enclosed miniature tension amplifi ers are powered by 24 VDC and output 0-to-10 Volt isolated signals proportional to tension. Take the output directly to a PLC or motor drive. iAmp connects to most DFE transducers and includes zero and calibration pot adjustments.
Inline Transducer Amplifier
TI 11 A dual-channel tension amplifi er on a single rack-mountable card. Used with one or two pair of transducers to measure or display web tension in one or two zones. The TI 11 card contains two independent tension circuits with independent calibration adjustments. IEC/ANSI/IEEE type 2 plug-in card installs into standard size 3U 19 inch rack or into optional mounting module.
Dual Transducer Interface/ Amplifier
» U/L listed
» Reduces risk of fire and explosion
» Easily adjusted with zero and calibration circuitry
» Contains a power supply for one or two transducers
» Protected in a compact, steel enclosure
» Compact tension transducer amplifier (2 x 3 x 1 inch)
» Saves space, expense and installation time versus standard amplifiers or interfaces
» Converts 0-to-500 mV transducer signal to 0-to-10 VDC isolated output for PLC, motor drive or other controller
» Includes 0-to-1 mA output for tension meter
» 24 VDC power input
» 0 to 10VDC output (proportional to tension) from each channel
» 0 to 1mAdc output proportional to tension for display meter
» Damping for tension meter output
» Rack-mountable interface for dual tension display or connection to controller
» Voltage and current outputs proportional to tension
» Optional plug-in cage for use outside of 19-inch rack
The compact WebHandler™3 digital tension controller takes automatic closed-loop web control to a new level of simplicity and performance at a highly competitive price. Standard features include touch panel setup and calibration with clear menus and text prompts, a large, backlit LCD display, compensation for speed and roll diameter, soft start, storage and recall of multiple job setups, and serial access via PC using included Windows-based software. Many options are also available.
Compact Digital Controller
The TensionManager™ Control Module is a microprocessor-based automatic web tension controller for OEMs and machinery builders. The compact controller is customizable with modular device add-ons, and easily confi gured for any web-fed converting or printing application. TensionManager™ allows direct tension measurement and control to be designed into machinery at a highly competitive cost.
Rack mount Digital Controller
DFE’s fl agship full-featured analog tension controller, renowned for its reliability, versatility, and ease-of-use. For use in unwind, intermediate, or rewind tension zones. Optional functions include taper tension, dual transducer input, DC and pulse tachometer inputs, and more. System status lights allow the operator to see the operating mode at a glance.
Standard Analog Controller
Automatic Tension ControllersSet your desired tension and the controller will maintain it. Easy-to-confi gure DFE controllers automatically compensate for variations in roll diameter, speed, and web material characteristics. Interchangeability of internal modular components between different controllers for features and options means fewer replacement components to stock.
All controllers offer» Choice of output modules to be used with an electric brake, pneumatic
brake or clutch, eddy current clutch or variable speed drive.
» Large, easy-to-view tension meters.
» Choice of enclosure styles.
» Standard emergency stop, auto/manual control modes, bumpless switching and soft start features.
Complete automatic turret rewind control system for automating a fl ying splice sequence. Combines advanced SteadyWeb™ tension control, core speed matching controls, fl ying-splice sequencing circuitry and a user-friendly interface. Turret rotation, knife fi ring, core speed matching, and tension control are coordinated all at the touch of a button.
Rewind Splicer System
Low-cost, automatic tension controller. Provides the superior performance of the SteadyWeb controller and the basic, required control features for most unwind and rewind applications. No frills package includes analog tension meter and user’s choice of outputs: 0-75 psi pneumatic, 0-90 VDC, 45 VDC, or 24 VDC and 0-10 VDC isolated and non-isolated.
Model WebHandler™3
» Low-cost, flexible, closed-loop tension control
» Space-saving device modules mount on a DIN-rail
» Program via remote terminal or computer
» Store/ recall up to 10 job setups
Model TensionManager™
Model SteadyWeb™
Low-cost Analog ControllerModel WebHandler™
Model SteadyWeb™ Splicer
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» Choice of control output including 0-75 psi pneumatic, 0-90 VDC, 45 VDC, 24 VDC, and 0-10 VDC isolated and non-isolated;
» 0-10 Volts DC tension signal output
» Auto/Manual control mode
» Emergency Stop feature
» Quick installation and setup
» Electric and pneumatic outputs
» 0-10 V and 4-20 mA tension outputs
» Rugged steel enclosure for superior protection
» Many options available
» Low-cost, automatic tension controller for unwind and rewind zones
» Compact size for quick, easy installation anywhere
» Controls electric or pneumatic clutches and brakes
» Tension controller with automatic rewind splice sequencing in one package
» Simple to install because all controls are in one enclosure
» Easy-to-use one-button splicing
Single Disk BrakeThe new 1D6D single disk pneumatic brake is the
perfect low-cost tensioning solution for unwind applications with low-torque requirements or installation space constraints. A single diaphragm provides low actuation force for low-tension applications. Corrosion-resistant materials allow the 1D6D to be used in wet environments.
Dual Disk BrakeSame high-performance as Dover’s Heavy-Duty dual disk brakes, but smaller and with a lower torque range. Easy to install and use, the 60 series brake was designed for lower tension unwind application in the converting, printing, composite, wire and fi lament industries. The brake can be confi gured for use with one cylinder or up to six cylinders.
» 9-inch to 18-inch diameter disks
» Heavy-duty brake for unwind applications
» Wide torque range
» Large heat dissipation capacity
» Hassle-free friction pad removal and installation— no tools required
» No Squeal warranty
With DFE’s Dual Disk Brakes worn friction pads can be changed in seconds, without tools. Limited travel pistons prevent disks from being scored. Cylinders can be actuated individually. Return spring cannot puncture diaphragm.
Available in fi ve standard sizes. Brakes fi t easily in place of other dual disk brakes. DFE’s universal style actuators can retrofi t brakes by other manufacturers.
Heavy Duty Dual Disk Brake
Pneumatic Tension BrakesDover brakes are an integral part of a high-performance unwind package. All of our brakes feature a limited travel piston that never scratches the disk, ductile iron disk construction, and expanded disk surface for rapid heat dissipation.
Our asbestos-free friction pads are available in several coeffi cients of friction. No tools are required to change the friction pads, making brake maintenance quick and “hassle free”.
To complement DFE’s 5-Year Warranty, 24/7 Technical Support and the rest of our standard customer care program, you will fi nd just what you need when it comes to spare parts and accessories. Order spare and replacement parts quickly, simply and securely online with a credit card. Stop by www.dfe.com to try it.
Spare Parts & Accessories
And much more…
• Fast turnaround • Reasonable prices • Major cards accepted
» Torque range from 1 lb-in. with one cylinder up to 1,000 lb-in. with six cylinders
» Cylinders can be actuated individually
» A range of pad friction coefficients is available to suit the application
» Replace worn pads in seconds without tools
» Compact, low-torque brake for smaller converting machines and specialty processes
» Brake can adapt to any shaft diameter ranging from ½” to 1 ¼”
» Optional rotation sensor interfaces with controls for computing roll diameter
Custom Engineered Application SolutionsAt DFE we base our entire success on our ability to deliver the most rugged, accurate and reliable control solutions on the market, whether they come off-the-shelf or custom-designed. A free application analysis from DFE will
determine whether or not a standard solution is appropriate. The products pictured represent a few DFE specials that were manufactured to fi t into less common applications.
In addition to a broad selection of off-the-shelf amplifi ers and display solutions, we can also easily customize most electronics products to include additional features. TLS (Tension Limit Switch), one of the more popular features on some of our amplifi ers and indicators, allows an alarm condition to be triggered when a high- or low-tension threshold has been reached. At your request, we’ve made TLS an available option on certain products, including the TI-5, which do not include TLS as a standard option.
A segmented Tension Roll® transducer designed to measure independent tension of 2 or more narrow webs running in parallel on a machine. For converters performing inline slitting and winding of fi lm and other extensible materials, gauge band variations across the substrate add a dimension of process variability that can make close control of tension on the resulting web strands critical. Roll face segment widths and spacing vary to your specifi cation.
DFE can package several controllers or tension display units into a single device to control or read tension easily in multiple zones. We will assist you with connection to computer or PLC via serial connection. This dual meter multiplexer display for a newspaper press reads out tension from 16 different sensing positions on each meter.
An application where the maximum bend radius of the substrate was a critical design factor. This special Tension Roll transducer with extended range, a 16-inch diameter roll and a 12-inch roll face was required in an application involving the chemical milling of very thin stainless steel strips. Certain coating processes also limit the bend radius of the substrate.
TLS Option Card
Segmented Tension Roll
Dual Meter Multiplexer Indicator
“Steamroller” Tension Roll® Transducer
Optical Fiber Winding WheelThe capabilities of DFE’s model RFA tension transducer are extended with this six-inch diameter adapter wheel. The special wheel transports optical fi ber in a quality control application while the transducer measures tension on the fi ber. The large diameter wheel prevents the glass core fi ber from bending beyond its breaking point.
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Tension Amplifier/ Interface.
1Product ComparisonTension Indicator Performance Features
FeatureFireGuard™
(Intrinsically
Safe)
TrueTension™
TI17C & TI 18C1
iAMP™ InlineTension Amplifier
TrueTension™
TI14
115/230 VAC operation · · TI 17C only · (230VAC option) ·24 VDC operation · · TI 18C only
Isolated 0 to 10V* output · (option) · · · (option) ·0 to 10V output* · · (all 3 channels) ·4 to 20 mA output* · · (option) ·0-20mA output · (option)
0 to 1 mA output* · ( x 2 ) · · · (0-100mV)· (energy
for remote tension meter limited)
Integrated analog tension meter · ·Available digital display/meter · (optional LED) · (optional LED) · (optional LED)
Meter damping · (dual) · · ·Available without enclosure · · (option)
Mounting styles: wm t, c, d wm, d wm wmwall or machine frame mount (wm)transducer mount (t)cable mount (c)DIN rail mount (d)
Note: Features and specifications are subject to change without notice.Refer to current DFE product data sheets or bulletins for available features, options and configurations.* All outputs proportional to tension1 Supersedes Model TI-17B/ 18B
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· (isolated)
Feature WebHandler™ 3(Digital)
SteadyWeb™
(Analog)WebHandler™ 2
(Analog)TensionManager™
(Digital)
115/230 VAC operation 24 Vdc input · · ·Auto and manual control modes · · · ·Choice of output modes: · · · ·
Non-isolated 0 to 10 V control output · · · · (or 0-1mAmeter output)
Non-isolated 4 to 20 mA control output · ·Non-isolated 0 to 10 V tension output · · ·Non-isolated 4 to 20 mA tension output ·Isolated 0 to 10 V control output (D version only) · (option) · (option) · ·Isolated 4 to 20 mA control or tension output · (option) · (option)