Automatic Web Tension Controller | Closed-Loop Tension Control System

TC-860 Automatic Web Tension Controller for Precise Closed-Loop Web Tension Control

Function-Focused Flagship Automatic Tension Controller for High-Precision Roll-to-Roll Processing

The XWDGM TC-860 Automatic Web Tension Controller is the function-focused flagship model of the TC Series, designed for precise closed-loop constant tension control in demanding winding, unwinding, and roll-to-roll processing applications.

Powered by a 32-bit high-speed CPU and a non-overshoot PI proportional-integral control algorithm, the TC-860 continuously receives real-time tension feedback from two tension sensors and automatically adjusts the connected actuator to maintain stable web tension throughout the production process.

The controller provides dual 24V/4A main outputs for directly driving magnetic powder brakes or magnetic powder clutches, together with dual 0–10V auxiliary analog outputs for connection to frequency inverters, servo drives, or compatible automation equipment.

With functions including dual-shaft switching, shaft-change output, standby output, acceleration and deceleration compensation, zero calibration, full-scale calibration, and optional RS485 / Modbus-RTU communication, the TC-860 is designed for machinery requiring more comprehensive tension control and system integration.

It is widely used in slitting, rewinding, printing, laminating, coating, paper converting, flexible packaging, textile, nonwoven, film, foil, and lithium battery material processing equipment.

High-Precision Closed-Loop Tension Control

The TC-860 operates as a complete closed-loop automatic tension controller.

Two tension sensors continuously measure the actual web tension and send feedback signals to the controller. The TC-860 compares the measured tension with the preset tension value and automatically adjusts the output to the magnetic powder brake, magnetic powder clutch, inverter, servo drive, or other compatible actuator.

This continuous feedback process helps maintain stable tension even when operating conditions change, including:

• Roll diameter changes
• Machine acceleration
• Machine deceleration
• Winding and unwinding transitions
• Roll changeover
• Material characteristics
• Production speed variation

This makes the TC-860 suitable for applications where stable tension is important for winding quality, material consistency, and reliable production.

32-Bit CPU and Non-Overshoot PI Algorithm

The TC-860 uses a 32-bit high-speed CPU together with a dedicated non-overshoot PI control algorithm.

The proportional and integral control strategy continuously corrects the tension according to real-time feedback while helping prevent excessive tension fluctuation during startup and operating transitions.

Key control characteristics include:

• 32-bit high-speed CPU
• Non-overshoot PI proportional-integral algorithm
• 50 ms sampling cycle
• 16-bit A/D conversion
• ±1 LSB conversion accuracy
• Two-point linear tension calibration

These functions provide the controller with fast feedback processing and precise signal measurement for automatic closed-loop tension regulation.

Dual Tension Sensor Input

The TC-860 supports two tension sensor input channels, allowing it to receive real-time feedback from a pair of tension detectors installed on the machine.

Standard sensor input ranges include:

• ±30 mV
• ±300 mV

A ±5V input configuration can also be customized according to the required sensor or machine control system.

The controller supports zero-point and full-scale calibration, allowing the tension detection system to be calibrated according to the actual sensor range and machine configuration.

When used with suitable tension sensors, the TC-860 forms a complete automatic closed-loop web tension control system.

Powerful Dual 24V/4A Main Outputs

The TC-860 provides two independent 24V/4A main output channels.

These outputs can directly drive compatible:

• Magnetic Powder Brakes
• Magnetic Powder Clutches

The dual main-output design provides greater flexibility for machines using two controlled tension actuators or dual-shaft winding and unwinding structures.

This makes the TC-860 particularly suitable for industrial machinery requiring more comprehensive automatic tension control than a basic single-output controller.

Dual 0–10V Auxiliary Outputs

In addition to the two 24V/4A main outputs, the TC-860 provides:

• 2 × 0–10V auxiliary analog outputs

These outputs can be connected to compatible:

• Frequency Inverters
• Servo Drives
• External Motor Control Systems
• Industrial Automation Equipment

The combination of dual 24V/4A outputs and dual 0–10V analog outputs gives OEM machinery manufacturers greater flexibility when integrating different tension actuators and drive systems.

Dual-Shaft Switching and Roll Change Control

The TC-860 includes dedicated functions for winding and unwinding machines using dual shafts or dual stations.

Available control functions include:

• Dual-shaft switching
• Shaft-change output
• Standby output
• Roll change control parameters
• Automatic output transition during shaft switching

These functions are designed to help reduce sudden output changes during roll replacement and switching between operating shafts.

For continuous or semi-continuous winding and unwinding machinery, this provides a more controlled transition between the active shaft and standby shaft.

Acceleration and Deceleration Compensation

Machine acceleration and deceleration can cause temporary changes in web tension.

The TC-860 includes acceleration and deceleration compensation functions that allow the tension control system to respond to these operating transitions.

This function is particularly useful for machinery with frequent:

• Start-stop operation
• Speed changes
• Production acceleration
• Production deceleration
• Winding and unwinding transitions

By combining tension feedback with compensation parameters, the controller provides additional control capability during dynamic machine operation.

Zero and Full-Scale Calibration

Accurate tension measurement depends on correct tension sensor calibration.

The TC-860 supports:

• Zero-point calibration
• Full-scale calibration
• Two-point linear calibration

This allows the controller to match the actual tension sensor installation and measurement range.

Proper calibration helps ensure that the displayed and controlled tension corresponds accurately to the real mechanical tension acting on the web.

RS485 / Modbus-RTU Communication

The TC-860 can be equipped with RS485 / Modbus-RTU communication for integration with PLCs and industrial automation systems.

Communication is optional depending on the controller configuration; the standard version can be supplied without the communication interface.

For Modbus-enabled configurations, the TC-860 provides a defined register mapping from 0x00 to 0x19, allowing compatible external control systems to access controller variables and operating status.

This makes the TC-860 suitable for OEM machinery requiring centralized control, PLC communication, production monitoring, or higher-level automation integration.

Graphic LCD and Menu-Based Operation

The TC-860 uses a 128 × 96 graphic LCD display with Chinese and English interface support.

Operators can configure controller parameters using:

• Numerical adjustment knob
• ▲ / ▼ adjustment keys
• Menu-based parameter settings

The interface allows operators and machine technicians to monitor tension values and configure operating parameters directly from the controller.

This combination provides convenient access to advanced functions while maintaining practical operation during installation, commissioning, and production.

Key Features

• Function-focused flagship model of the TC Series
• Fully automatic closed-loop constant tension control
• 32-bit high-speed CPU
• Non-overshoot PI control algorithm
• 50 ms sampling cycle
• 16-bit A/D conversion
• ±1 LSB conversion accuracy
• Two tension sensor inputs
• ±30mV / ±300mV sensor input
• Optional customized ±5V input
• Dual 24V/4A main outputs
• Direct drive for magnetic powder brakes and clutches
• Dual 0–10V auxiliary outputs
• Compatible with inverters and servo drives
• Dual-shaft switching
• Shaft-change output
• Standby output
• Acceleration and deceleration compensation
• Zero-point calibration
• Full-scale calibration
• Two-point linear tension calibration
• Optional RS485 / Modbus-RTU communication
• Defined Modbus register mapping
• 128 × 96 graphic LCD
• Chinese and English interface
• AC 165–264V wide-range power supply

Benefits of Automatic Web Tension Control

Maintaining stable web tension is critical to consistent roll-to-roll production.

When correctly integrated with the appropriate sensors and actuators, the TC-860 can help manufacturers achieve:

• Stable winding and unwinding tension
• Improved slitting consistency
• Improved winding quality
• Reduced tension fluctuation
• Reduced material wrinkles
• Reduced stretching
• Reduced telescoping tendency
• Lower material waste
• Reduced operator adjustment
• More consistent finished rolls
• Improved production stability

Its closed-loop architecture continuously responds to actual measured tension rather than relying only on manually preset output values.

Applications

The XWDGM TC-860 Automatic Web Tension Controller is suitable for:

• Slitting Machines
• Rewinding Machines
• Unwinding Machines
• Rotogravure Printing Machines
• Flexographic Printing Machines
• Coating Machines
• Laminating Machines
• Paper Processing Equipment
• Film Converting Equipment
• Foil Processing Equipment
• Flexible Packaging Machinery
• Label Converting Machines
• Textile Machinery
• Nonwoven Production Lines
• Lithium Battery Electrode Processing Lines
• Roll-to-Roll Processing Equipment
• Dual-Shaft Winding and Unwinding Systems

Its combination of high-speed feedback processing, dual main outputs, dual auxiliary outputs, compensation functions, shaft-switching control, and optional Modbus communication makes it particularly suitable for machines requiring comprehensive automatic tension control.

System Integration

The Automatic Web Tension Controller can be integrated with:

[ Through-Shaft Tension Sensor]

Provides accurate web tension feedback for closed-loop control.

[Magnetic Powder Brake]

Delivers precise braking torque regulation for unwind tension control.

[ Magnetic Powder Clutch]

Provides smooth torque transmission for rewind and process tension control.

[Web Guiding System]

Improves web alignment and tracking performance during production.

[Tension Control System]

Build a complete web handling and tension management solution.

Technical Specifications

Item	Specification
Product Name	TC-860 Automatic Web Tension Controller
Series	TC Series
Product Positioning	Function-Focused Flagship
Control Type	Fully Automatic Closed-Loop Constant Tension
Processor	32-Bit High-Speed CPU
Control Algorithm	Non-Overshoot PI Algorithm
Sampling Cycle	50 ms
A/D Conversion	16-Bit
Conversion Accuracy	±1 LSB
Tension Calibration	Two-Point Linear Calibration
Sensor Input	2 Channels
Standard Input Range	±30mV / ±300mV
Optional Input	±5V Customized
Main Output	2 × 24V/4A
Main Output Application	Magnetic Powder Brake / Magnetic Powder Clutch
Auxiliary Output	2 × 0–10V
Auxiliary Output Application	Inverter / Servo Drive / External Control
Dual-Shaft Switching	Supported
Shaft-Change Output	Supported
Standby Output	Supported
Acceleration/Deceleration Compensation	Supported
Communication	Optional RS485 / Modbus-RTU
Modbus Register Mapping	0x00–0x19
Display	128 × 96 Graphic LCD
Interface Language	Chinese / English
Operation	Numerical Knob + ▲ / ▼ Keys
Power Supply	AC 165–264V
Application	Automatic Closed-Loop Web Tension Control

Why Choose XWDGM TC-860?

Function-Focused Flagship TC Series Controller

The TC-860 is positioned as the function-focused flagship automatic tension controller of the TC Series.

Compared with simpler automatic tension controllers focused primarily on basic tension adjustment, the TC-860 provides a more comprehensive combination of:

• High-speed closed-loop feedback
• Non-overshoot PI control
• Dual 24V/4A outputs
• Dual 0–10V outputs
• Dual-shaft switching
• Acceleration/deceleration compensation
• Shaft-change and standby outputs
• Tension sensor calibration
• Optional PLC communication

This makes the TC-860 suitable for machinery requiring a broader range of automatic tension control functions.

High-Precision Feedback Processing

The combination of a 32-bit CPU, 50 ms sampling cycle, 16-bit A/D conversion, and two-point linear calibration provides the controller with precise tension signal processing for closed-loop operation.

This is particularly useful for roll-to-roll machinery where tension conditions change continuously during production.

Flexible Actuator Integration

The TC-860 can directly drive magnetic powder brakes and magnetic powder clutches through its dual 24V/4A outputs.

Its dual 0–10V auxiliary outputs also allow integration with compatible frequency inverters and servo systems.

This provides machine builders with greater flexibility when designing different winding, unwinding, and process tension control architectures.

Advanced Dual-Shaft and Dynamic Control

Functions such as dual-shaft switching, shaft-change output, standby output, and acceleration/deceleration compensation make the TC-860 particularly suitable for more complex winding and unwinding machinery.

These functions help the controller manage operating transitions beyond basic constant tension regulation.

Industrial Automation Integration

Optional RS485 / Modbus-RTU communication allows the TC-860 to communicate with compatible PLC and industrial control systems.

The defined register mapping provides a practical interface for machine manufacturers requiring external parameter access, operating status monitoring, or centralized automation control.

Complete XWDGM Tension Control Solution

The TC-860 can be combined with XWDGM tension sensors, magnetic powder brakes, magnetic powder clutches, web guiding systems, and other web handling components to create a complete automatic tension management solution.

XWDGM supports product selection, component matching, system integration, OEM requirements, and after-sales technical support for global winding, unwinding, printing, converting, packaging, and roll-to-roll processing applications.

Frequently Asked Questions

What is an Automatic Web Tension Controller?

An Automatic Web Tension Controller is a closed-loop control device that maintains constant web tension by processing signals from load cells or tension sensors and automatically adjusting brakes, clutches, or drive systems.

How does a Closed-Loop Tension Controller work?

The controller continuously compares actual tension feedback with the target tension value. It automatically adjusts output torque to maintain stable web tension throughout the production process.

What is the difference between open-loop and closed-loop tension control?

Open-loop systems estimate tension based on roll diameter calculations, while closed-loop tension controllers use actual feedback from tension sensors or load cells to achieve higher accuracy and stability.

Which machines use Automatic Web Tension Controllers?

Automatic Web Tension Controllers are widely used in slitting, rewinding, printing, laminating, coating, flexible packaging, paper converting, and lithium battery manufacturing equipment.

Can this controller work with magnetic powder brakes and clutches?

Yes. The XWDGM Automatic Web Tension Controller is designed to work seamlessly with magnetic powder brakes, magnetic powder clutches, pneumatic brakes, and other torque control devices to achieve precise web tension regulation.

Can the controller connect to load cells and tension sensors?

Yes. The controller supports load cell feedback and various tension sensor configurations, enabling highly accurate closed-loop tension control for demanding industrial applications.