Description

ABB PFEA113-20 3BSE028144R0020

1. Basic Information

ABB PFEA113-20 (Part No. 3BSE028144R0020) is a high-precision tension measurement and control electronic unit of ABB PFEA series. Specially designed for closed-loop tension control of continuous web production lines, it serves as the core tension regulation module for paper making, film, textile, printing and metal foil industries. It directly connects load cell tension sensors to complete tension signal acquisition, amplification, operation, closed-loop regulation and data output, eliminating process defects such as web looseness, wrinkles, stretching, deviation and uneven thickness during winding and unwinding, and ensuring constant tension and stable process throughout web production.

Equipped with a high-performance processing chip, the module integrates full functions including signal conditioning, high-precision AD conversion, multi-mode PID regulation, bus communication and fault diagnosis. It supports access of up to 4 tension sensors to adapt to multi-station, wide-width and high-speed web production lines. Featuring ultra-high steady-state control accuracy, millisecond-level dynamic response and adaptive taper tension algorithm, it supports switching of tension, speed and position multi-mode control. With industrial anti-interference design, it adapts to harsh working conditions of production line high vibration, frequency conversion interference and long-term high-speed operation. It is widely used for new production line tension system matching, old tension module replacement and web process accuracy upgrading.

2. Technical Specifications

2.1 Core Tension Control Specifications

Product Positioning: High-precision industrial web tension measurement and control module, supporting up to 4 load cell sensor inputs for complex multi-point tension monitoring scenarios
Control Accuracy: Steady-state accuracy ±0.1%FS, dynamic acceleration/deceleration accuracy ±1% of set value, leading industrial tension control level
Response Speed: Dynamic response time ≤10ms, control cycle 10ms, perfectly adapting to dynamic working conditions of high-speed web start-stop and acceleration/deceleration
Tension Range: Standard 0.1–2000N, expandable to 5000N, covering full-range tension regulation requirements for light, medium and heavy webs
Control Modes: Constant tension control, linear/S-type taper tension control, speed control, position limit and current limit protection multi-mode switchable
Process Algorithm: Built-in adaptive tension compensation algorithm automatically corrects tension deviation between inner and outer layers and web head/tail to improve finished product yield

2.2 Electrical Power Specifications

AC Power Supply: 100V(-15%)～240V(+10%) AC, compatible with universal industrial AC power supply
DC Power Supply: 24V DC wide-range input (18–36V DC), tolerant to on-site voltage fluctuation and instantaneous voltage drop
Power Frequency: 45–65Hz for AC power supply
Power Consumption: Max 12W, low-power design with low temperature rise and high stability under long-term full-load operation
Sensor Excitation: 330Hz, 0.5A RMS constant-current excitation output ensuring stable and drift-free sensor signal output

2.3 I/O Signal Specifications

Input Channels: 4 configurable differential load cell tension sensor inputs for synchronous multi-point tension collection
Analog Output: Multi-channel high-precision analog output, standard 0–10V / 4–20mA, compatible with frequency converters, servos and tension actuators
Digital Ports: Configurable digital I/O for start-stop interlock, fault reset, working mode switching and limit protection
Signal Accuracy: 12-bit high-precision signal conversion with excellent linearity, no segment deviation or temperature drift distortion
Isolation Protection: Full electrical isolation for input and output, effectively isolating frequency conversion interference, industrial clutter and ground crosstalk

2.4 Communication & Operation Specifications

Core Performance: High-performance industrial processor with high-speed parallel operation and millisecond-level closed-loop response
Communication Protocols: Natively supports Profibus-DP, RS485, Modbus and Ethernet for seamless connection with upper PLC and industrial control systems
Data Interaction: Real-time upload of measured tension value, set value, equipment status and fault codes, supporting remote parameter tuning and monitoring
Parameter Storage: Built-in power-off memory function saves process parameters without reconfiguration after restart

2.5 Diagnosis & Protection Specifications

Power-on Self-inspection: Automatically completes full-dimensional self-inspection of sensor loops, power supply, chips and communication ports upon power-on
Real-time Diagnosis: Continuously monitors sensor disconnection, over-range, abnormal tension, communication timeout and load faults
Multi-protection: Tension over-limit, speed over-limit, position limit, overload current limiting and short-circuit self-locking protection
Fault Output: Automatically locks tension output and triggers system alarms under abnormal conditions to avoid web breakage, loose winding and equipment overload damage

2.6 Environmental & Physical Specifications

Operating Temperature: -20℃～+60℃ wide temperature range, adapting to normal high and low temperature workshop production environments
Storage Temperature: -40℃～+85℃, strong temperature impact resistance and anti-aging performance during storage and transportation
Humidity Range: 5%～95% (non-condensing), dust-proof and moisture-proof for high-humidity workshop conditions
Protection Grade: IP20, suitable for installation in standard industrial control cabinets
EMC Performance: Compliant with industrial EMC standards with excellent resistance to frequency conversion interference, electromagnetic radiation and power clutter
Installation Mode: Standard rail mounting with convenient assembly and disassembly, vibration-proof and anti-loose for high-vibration production line conditions

3. Working Principle

Power-on Initialization & Self-inspection: After AC/DC power-on, the module automatically completes hardware self-inspection, communication protocol initialization, sensor loop detection and process parameter loading, verifies channel integrity and equipment compatibility, and enters standby measurement and control state after passing inspection.
Synchronous Multi-channel Tension Acquisition: It synchronously collects real-time web tension signals through 4 sensor interfaces, eliminates on-site vibration, frequency conversion interference and signal clutter via differential input, hardware filtering and signal shaping, and obtains pure original tension data.
High-precision Data Operation: The high-speed processor completes tension data calibration, temperature compensation and linear correction, calculates closed-loop adjustment deviation by comparing measured values with set values based on preset constant or taper tension process models.
Dynamic Closed-loop Tension Regulation: It outputs accurate analog control signals to drive frequency converters, servo motors, tension brakes and other actuators, dynamically adjusts winding/unwinding speed and torque, eliminates tension deviation in real time, and maintains constant web tension.
Multi-mode Process Adaptive Control: It automatically switches S-type/linear taper tension algorithms during production line start-stop, acceleration/deceleration and winding finishing stages, compensates tension fluctuation caused by coil diameter change, and avoids web stretching, wrinkles and deviation defects.
Data Upload & Fault Protection: It uploads tension working conditions and equipment status in real time via bus, monitors loop abnormalities and process faults throughout operation, automatically locks control output, triggers alarms and executes protective shutdown under faults to ensure production line and material safety.

4. Application Scenarios

4.1 Paper Making & Paper Processing Production Line

Widely used in tension control systems of paper machines, rewinding machines, slitting machines and coating machines, it accurately controls winding/unwinding tension to solve problems such as thin paper stretching, paper breakage, wrinkles and uneven winding tightness, greatly improving paper flatness and finished product yield, adapting to high-speed continuous paper making conditions.

4.2 Film, Plastic & Flexible Material Production Line

Suitable for PE, PET, PVC film, non-woven fabric and plastic coil production equipment. High-precision constant tension control avoids flexible material stretching deformation, thickness deviation and winding deviation, meeting high-precision process requirements of film coating, lamination, slitting and printing.

4.3 Textile, Dyeing & Printing Automatic Production Line

Applied in tension regulation of textile grey fabric, dyeing, printing and coating equipment, it adapts to flexible fabric material characteristics, dynamically compensates tension fluctuation during start-stop, and prevents fabric looseness, wrinkles and stretching deformation to ensure consistent textile processing accuracy and appearance quality.

4.4 Metal Foil, Cable & Precision Coil Industry

Used in winding/unwinding control of precision hard coils such as aluminum foil, copper foil, steel strip and cables, it adapts to heavy-duty high-tension working conditions, accurately suppresses high-speed tension oscillation, and prevents metal coil deformation, warpage and interlayer displacement to meet precision industrial coil production standards.

4.5 Upgrading & Replacement of Old Production Line Tension Systems

It is fully compatible to replace various old ABB and universal tension control modules, solving common problems of old equipment such as poor tension accuracy, large fluctuation, high-speed runaway and high failure rate. It upgrades production line process accuracy and stability at low cost without large-scale wiring and program modification.