Description

ABB PFTL101B-20.0kN 3BSE004203R1

ABB PFTL101B-20.0kN (Order No.: 3BSE004203R1) is a heavy-load high-precision tension/load cell under ABB's Pressductor® magnetoelastic technology platform, belonging to the Pillow Block load cell series. Specifically designed for the accurate measurement of high tension, high pressure and heavy-load weight within the 20.0kN range in industrial scenarios, it is the core main model of ABB's heavy-load tension measurement product line. Relying on the unique advantages of magnetoelastic technology combined with a reinforced structural design, this sensor can operate stably in various harsh industrial environments, and is widely used in heavy-load tension control and high-precision weighing scenarios, suitable for complex working conditions such as heavy rolls and high-speed production lines.

1. Working Principle and Structural Features

This sensor achieves precise force measurement based on the magnetoelastic effect (also known as piezomagnetic effect): when mechanical force acts on the measuring assembly, the magnetic permeability of the internal material changes regularly. A dedicated detection circuit converts this change in magnetic permeability into a stable and accurate electrical signal, and finally completes the force measurement. Compared with traditional strain gauge sensors, its non-contact and wear-free measurement method fundamentally solves the problems of strain gauges being prone to fatigue, short service life and intolerance to heavy loads, and also has stronger anti-interference ability and long-term operation stability, with almost no built-in limit on the number of load cycles.

Structurally, it adopts a heavy-load reinforced compact design, mainly composed of a measuring assembly (FR), a force conversion assembly (FV) and a 316L stainless steel housing. The housing is hermetically sealed by laser welding, with an IP67 protection rating, which can effectively resist the impact of harsh environmental factors such as dust, humidity, corrosive gas and strong vibration, and is suitable for severe industrial scenarios such as paper machine wet ends and steel mills. As a horizontal-measurement pillow block sensor, it supports both horizontal and inclined installation methods, which is easy to install and highly adaptable, and can be flexibly integrated into various heavy-load industrial equipment and high-speed production lines. It is installed under the roll bearings to measure forces parallel to the mounting surface.

2. Core Technical Specifications

All technical specifications of the sensor have been strictly factory-calibrated, with excellent precision and stability. The core parameters are as follows (integrating authoritative calibration values to ensure accuracy and referability, suitable for 20.0kN heavy-load specifications):

Rated Load: 20.0kN (i.e., 20000N, approximately 4500lbs, equivalent to 2040 kilogram-force);
Measurement Accuracy: ±0.2% full scale (F.S.), up to ±0.25% FSO in 220V AC power supply scenarios, comprehensive error ≤0.03% F.S. (compliant with Class C3 accuracy standard), repeatability error ＜0.05% F.S.;
Nonlinearity: ±0.05% F.S., Hysteresis: ±0.03% F.S., Repeatability: ±0.02% F.S.;
Creep Performance: Creep ≤±0.02% F.S. within 30 minutes, annual drift rate ≤±0.02% F.S., with outstanding long-term stability;
Output Signal: Standard 2.0mV/V analog signal (based on excitation voltage); optional 4-20mA DC signal (matching signal converter required), supporting high-power, low-impedance AC signal output;
Excitation Parameters: Operating voltage is 220V AC, 12-24V DC wide voltage supported in some scenarios; maximum excitation current 60mA, low-power design;
Response Performance: Response time ≤5ms, equipped with a dynamic high-speed calculation circuit, real-time data processing up to 125μs, millisecond-level dynamic response, suitable for high-speed winding equipment above 1000m/min, capable of capturing tiny tension fluctuations;
Overload Capacity: Maximum overload 25.0kN in measurement direction, allowable transverse load 40.0kN, axial overload 25.0kN, with ultra-strong overload tolerance, effectively avoiding damage caused by accidental overload, perfectly combining sensitivity and overload tolerance;
Physical Characteristics: Deflection 0.01mm, spring constant 500kN/mm, extremely high structural rigidity, no obvious deformation during measurement, and can maintain stable output even under severe vibration; cable specification is 4x AWG17, bending radius is 10 times the cable diameter;
Operating Environment: -40℃~+85℃ (partially calibrated -25℃~+90℃, subject to actual working conditions), ambient humidity 0-95%, IP67 protection rating, dust-proof and short-time water immersion resistant;
Electrical Protection: Built-in radio frequency interference filter, with multiple protections of overload, short circuit and open circuit, strong anti-electromagnetic interference ability, suitable for strong electromagnetic environments such as steel mills and chemical plants;
Others: Supports single-point grounding, parallel power supply and redundancy technology; factory pre-calibrated, ready to use after unboxing, no on-site calibration required; certified to CE, UL and CSA standards, with continuous self-diagnosis function, and can be debugged with or without ropes and weights; annual drift rate ≤±0.02% F.S.

3. Core Product Advantages

High Precision and Stability: Magnetoelastic core technology + strict factory calibration, compliant with Class C3 accuracy standard, high precision, small drift; non-contact measurement principle reduces wear, service life up to 15 years, reducing equipment replacement frequency by 60%, with almost no limit on the number of load cycles;
Strong Heavy-Load Adaptability: Specifically designed for 20.0kN heavy-load scenarios, reinforced structure combined with high-rigidity physical characteristics, high spring constant and small deflection, can stably bear heavy-load pressure and tension, suitable for heavy-roll working conditions;
Harsh Environment Adaptability: 316L stainless steel sealed housing + IP67 protection, laser welding technology, capable of stable operation in humid, dusty, highly corrosive, strong vibration, high and low temperature scenarios, suitable for special harsh environments such as paper machine wet ends; some derivative models can achieve acid-resistant design;
Outstanding Anti-Interference: Built-in radio frequency interference filter, high-power low-impedance AC output, extremely strong resistance to electrical interference and ground fault, suitable for industrial scenarios with strong electromagnetic interference;
Easy Installation and Integration: Supports horizontal/inclined installation, requires matching PFTL101B dedicated adapter plate (minimum thickness 38mm), suitable for installation under roll bearings, no complex debugging, and can be flexibly integrated into various heavy-load production lines;
High Compatibility: Seamlessly connects with ABB PFEA series tension controllers, compatible with various PLC and DCS systems, supports Profibus communication function and optional filtering function, can be used in parallel and configured with redundancy, and has maximum load memory function;
Low Maintenance Requirement: The robust heavy-load design and non-contact measurement principle greatly reduce wear and maintenance needs, lowering late-stage operation and maintenance costs.

4. Application Scenarios

As a heavy-load high-precision measurement device, it is suitable for tension detection of heavy-load strips, thick wires, thick plates and other materials, as well as pressure monitoring and heavy-load weighing of large industrial equipment. It is widely used in occasions with low tension levels, heavy rolls and high operating speeds, including:

Metal Processing: High tension control of large steel rolling and thick strip processing lines, accurate measurement of ultra-high tension, ensuring processing accuracy and reducing defective rate; also suitable for tension measurement and control of thick metal wire processing lines;
Paper Making Industry: Used in equipment such as wet ends, presses, encoders and winders of paper machines to accurately measure web tension, suitable for paper production lines with heavy rolls and high operating speeds, and can provide long-term stable high-precision tension data in the drying section of paper machines;
Cable Manufacturing: Used for tension control in the production of heavy machinery cables to ensure consistent cable quality, suitable for tension monitoring scenarios of heavy-load cables;
Other Fields: Large-scale textile fabric tension control in the textile industry, heavy-load weighing of large automated production lines, pressure monitoring of heavy material handling equipment, as well as heavy-load precision weighing and tension control in chemical and building materials production (suitable for heavy-load scenarios with heavy rolls, wide tension range, high operating speed and high precision requirements); also can be used for heavy-load tension control of large printing machines and packaging machinery in the printing and packaging industry.