描述
一、产品定位与核心功能
1.目标应用场景
金属压延与轧制：
在冷轧、热轧生产线中，控制带钢、铝箔等金属卷材的张力，确保轧制厚度均匀，减少边裂或断带风险。
纺织与无纺布生产：
用于纺纱机、织布机、涂层机，调节纱线、布料的张力，防止织物松弛或拉伸过度，提升面料平整度。
造纸与包装行业：
在复卷机、分切机、印刷机中，控制纸张、薄膜、标签的张力，避免印刷套色偏差或材料浪费。
电线电缆制造：
调节铜线、铝线在挤出、绕包、成缆过程中的张力，确保线缆直径一致，减少绝缘层偏心。
2.核心功能
闭环张力控制：
通过模拟量输入（0-10V/4-20mA）接收张力传感器信号，结合PID控制算法，实时调整驱动电机转速或制动扭矩，实现张力恒定。
多模式控制：
支持速度模式、转矩模式、直接张力模式，可根据工艺需求灵活切换（如启动阶段用速度模式，稳态用张力模式）。
动态响应优化：
内置自适应滤波器和前馈补偿，抑制机械振动、速度突变对张力的干扰，响应时间<50ms，适用于高速生产线（如每分钟1000米以上）。
故障诊断与保护：
监测过张力、欠张力、传感器故障、通信中断等异常，通过继电器输出或现场总线触发报警或急停，保障设备安全。
二、技术规格与性能参数
1.电气参数
电源输入：
AC 85-265V（50/60Hz）或DC 24V（18-30V），适应不同国家电网或UPS供电。
控制精度：
张力控制误差：±0.5%FS（满量程），满足高精度加工需求（如光学薄膜生产）。
信号接口：
模拟量输入：2路（0-10V/4-20mA），可连接张力传感器、速度传感器。
模拟量输出：2路（0-10V/4-20mA），用于驱动器控制或HMI显示。
数字量输入/输出：4路DI（可编程为启动、停止、复位等），2路DO（用于报警、状态指示）。
通信接口：支持Modbus RTU（RS485）、CANopen、Profibus-DP，可与PLC、SCADA系统集成。
2.机械参数
外壳防护等级：
IP20（标准版），适用于控制柜内安装；可选IP65防护罩（需单独订购），用于户外或粉尘环境。
安装方式：
35mm DIN导轨安装或面板安装，尺寸144mm（宽）×144mm（高）×50mm（深），占用空间小。
重量：
约1.2kg，便于快速部署或更换。
3.环境适应性
工作温度：
-10℃至+55℃（存储温度：-25℃至+70℃），适应高温车间（如冶金行业）或寒冷地区。
湿度：
5%-95%RH（无凝露），耐受潮湿环境（如造纸厂）。
抗振动：
通过IEC 60068-2-6标准振动测试（频率10-55Hz，振幅1.5mm），确保在机械振动环境下稳定运行。
三、产品特点与优势
1.高精度与稳定性
双闭环控制：
结合张力环（主环）和速度环（副环），消除速度波动对张力的影响，例如在加速/减速阶段仍能保持张力恒定。
传感器冗余设计：
支持双传感器输入，当主传感器故障时自动切换至备用传感器，避免生产中断。
2.灵活性与易用性
参数自整定：
通过一键自整定功能，自动计算PID参数，减少调试时间（传统调试需2-4小时，自整定仅需10分钟）。
多语言HMI：
配备2.4英寸彩色液晶屏，支持中文、英文、德文等8种语言，操作界面直观，便于本地化使用。
可编程逻辑：
内置简易PLC功能，可通过功能块图（FBD）编写自定义控制逻辑（如张力分段控制、联动控制），无需外部PLC。
3.兼容性与扩展性
多品牌驱动器支持：
可控制ABB、西门子、SEW、Lenze等品牌变频器或伺服驱动器，通过模拟量或现场总线通信实现无缝对接。
扩展模块选项：
可选配IO扩展模块（增加8路DI/DO）或温度控制模块，满足复杂工艺需求（如同时控制张力和温度）。
I.Product Positioning and Core Functions
1.Target Application Scenarios
Metal Calendering and Rolling:
In cold and hot rolling production lines,this device controls the tension of metal coils such as steel strip and aluminum foil to ensure uniform rolled thickness and reduce the risk of edge cracking or breakage.
Textile and Non-woven Fabric Production:
Used in spinning machines,looms,and coating machines,this device adjusts the tension of yarn and fabric to prevent fabric sagging or excessive stretching,thereby improving fabric smoothness.
Paper and Packaging Industry:
In rewinders,slitters,and printing presses,this device controls the tension of paper,film,and labels to prevent color misregistration and material waste.
Wire and Cable Manufacturing:
This device adjusts the tension of copper and aluminum wires during extrusion,wrapping,and cabling to ensure consistent cable diameter and reduce insulation eccentricity.2.Core Functions
Closed-Loop Tension Control:
The tension sensor signal is received via an analog input(0-10V/4-20mA).Combined with a PID control algorithm,the drive motor speed or braking torque is adjusted in real time to maintain constant tension.
Multi-Mode Control:
Supports speed mode,torque mode,and direct tension mode,with flexible switching based on process requirements(e.g.,speed mode during startup,tension mode during steady state).
Dynamic Response Optimization:
Built-in adaptive filters and feedforward compensation suppress tension disturbances caused by mechanical vibration and sudden speed changes.With a response time of less than 50ms,it is suitable for high-speed production lines(e.g.,over 1000 meters per minute).
Fault Diagnosis and Protection:
Detects anomalies such as overtension,undertension,sensor failure,and communication interruption,triggering alarms or emergency stops via relay outputs or fieldbus to ensure equipment safety.II.Technical Specifications and Performance Parameters
1.Electrical Parameters
Power Input:
AC 85-265V(50/60Hz)or DC 24V(18-30V),compatible with power grids or UPS in different countries.
Control Accuracy:
Tension Control Error:±0.5%FS(Full Scale),meeting high-precision processing requirements(such as optical film production).
Signal Interface:
Analog Input:2 channels(0-10V/4-20mA),compatible with tension and speed sensors.
Analog Output:2 channels(0-10V/4-20mA),for drive control or HMI display.
Digital Input/Output:4 DI channels(programmable for start,stop,reset,etc.),2 DO channels(for alarm and status indication).
Communication Interface:Supports Modbus RTU(RS485),CANopen,and Profibus-DP,enabling integration with PLC and SCADA systems.2.Mechanical Parameters
Enclosure Protection Rating:
IP20(standard version),suitable for installation in a control cabinet;optional IP65 protective cover(ordered separately)for outdoor use or dusty environments.
Mounting Method:
35mm DIN rail or panel mounting.Dimensions:144mm(W)×144mm(H)×50mm(D),compact.
Weight:
Approximately 1.2kg,allowing for quick deployment or replacement.
3.Environmental Adaptability
Operating Temperature:
-10°C to+55°C(Storage Temperature:-25°C to+70°C),suitable for high-temperature workshops(such as those in the metallurgical industry)or cold regions.
Humidity:
5%-95%RH(non-condensing),suitable for humid environments(such as paper mills).
Vibration Resistance:
Passed the IEC 60068-2-6 vibration test(frequency 10-55Hz,amplitude 1.5mm),ensuring stable operation in mechanical vibration environments.III.Product Features and Advantages
1.High Precision and Stability
Dual Closed-Loop Control:
Combining the tension loop(primary loop)and the speed loop(secondary loop)eliminates the effects of speed fluctuations on tension,maintaining constant tension during acceleration and deceleration.
Sensor Redundancy:
Supports dual sensor inputs.Automatically switches to the backup sensor if the primary sensor fails,avoiding production interruptions.
2.Flexibility and Ease of Use
Parameter Auto-Tuning:
One-click auto-tuning automatically calculates PID parameters,reducing commissioning time(traditional commissioning takes 2-4 hours,while auto-tuning takes only 10 minutes).
Multilingual HMI:
Equipped with a 2.4-inch color LCD screen supporting eight languages,including Chinese,English,and German,the intuitive user interface facilitates localization.
Programmable Logic:
Built-in simple PLC functionality allows custom control logic(such as tension stage control and linkage control)to be programmed using Function Block Diagram(FBD),eliminating the need for an external PLC.3.Compatibility and Scalability
Multi-Brand Drive Support:
Controls inverters or servo drives from brands such as ABB,Siemens,SEW,and Lenze,achieving seamless integration via analog or fieldbus communication.
Expansion Module Options:
Optional I/O expansion modules(adding 8 DI/DO channels)or temperature control modules are available to meet complex process requirements(such as simultaneous tension and temperature control).
ABB Model: GBU72 3BHE055094R0002 Model: 3BHE055094R0002 GBU72 Model: GBU72 Model: 3BHE055094R0002 Model: 3BHE031197R0001 Model: 3BHB030310R0001 Model: 73BHE055094R0002 GBU72 Model: 73BHE055094R0002 Model: GBU72 Model: ABB PCS6000 PRODUCT FAMLIY ABB 5SHY4045L0006 3BHB030310R0001 3BHE039203R0101 GVC736CE101
