Web tension in paper

production:
Challenges and
solutions

March 28

FMS Force Measuring Systems AG

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Solving the complex challenges of web tension
measurement in paper production and processing
The demands on producers and machine builders in the paper industry are
on the rise. You’re being called on to produce more cost-efficient products
of higher quality while at the same time driving productivity and
profitability. To do this, you need to take advantage of the latest advances
in automation, control and drive technology. And the basis of this is web
tension measurement.
The challenges of web tension measurement
Web tension is an important factor in paper production. Constant tension is crucial to maximize product
quality and overall productivity. The technology required for this must be durable enough to withstand
extreme conditions. Depending on the installation location, high temperatures, humidity, vibrations and
overload are frequently encountered as well as low web tension with high roller weights and speeds.
Force sensors in these environments are exposed to extreme loads yet must be very sensitive to
guarantee measurement accuracy. At the same time, they must be capable of measuring the widest
possible range of web tensions. On top of this, they must be utterly reliable. Downtime due to
malfunction of these components is costly. In addition, poor product quality or an unstable production
process may also indicate that the force sensors you are using are not up to the task.

The importance of tension monitoring throughout production processes

In a typical Fourdrinier machine, continuous tension monitoring is already used at the transition from
the headbox to the wet end of the machine. The paper is still in suspension in the wet section. Force
sensors here measure the web tension of the endless wire mesh. The same applies to the felt section,
where force sensors measure the tension of the felt. Sometimes the contact pressure of the rollers in
press nips are equipped with force sensors to detect the exact line force. From the dryer section
onwards, the tension of the paper web is measured to minimize the risk of breaks. Continuous
measurement and precise measurement signals are essential for this. Finally, the last measuring point
is in the reel section, just before the spool.
Web tension monitoring is also indispensable in downstream processes such as slitting, laminating,
and coating systems and also in printing machines.
Addressing the challenges: FMS force measuring blocks
For web tension measurement in the dryer section, we recommend our UMGZ-series. Depending on
the residual moisture and temperature, the technical properties (and costs) can be optimally adjusted
to the ambient conditions. This ensures accurate and reliable measurement and a long service life.
The robust PMGZ-series was developed for use in the wet section and is rated IP67. The stainless-
steel design and its special sealing with glass feed-through make the measuring body insensitive to
any aggressive media. As additional protection, our strain gauges operate in a hermetically sealed inert
gas atmosphere. The robust construction with increased rigidity is designed to withstand machine and
web vibrations at the highest production speeds.
Our force sensors are maintenance-free and wear-free and therefore offer maximum availability. They
are not subject to zero-point drift and offer the best repeatability. They also withstand overloads of up
to 10 -times their nominal force. The mechanical hard stop prevents damage caused by unintentional
overloading.

FMS: A key player in the paper industry

FMS Force Measuring Systems has been providing web tension measurement solutions to
customers in the paper industry (including tissue and cardboard) for over three decades. As the
market leader for tension monitoring components, we continuously develop our products to stay one
step ahead of the needs of the industry.

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Our three series of force sensors offer high flexibility and optimum performance for their respective
installation location.
UMGZ-series – the all-rounder
8 sizes, nominal force from 0.25 to 100 kN (55 to 22'500 lbf)
Many standard options and room for customization
PMGZ-series – specialist for the wet section
5 sizes, nominal forces from 1 bis 80 kN (225 to 18'000 lbf)
IP67 rated
UMGZP-series – direct replacement for Philips PR 9951
Drop-in-replacement of the earlier Philips-series PR 9951B, PR 9952B
When producing paper, every single minute of running time counts. With FMS force sensors, you know
you’re getting maximum reliability.
FMS measuring amplifiers
Continuous monitoring of web tension is a basic requirement for web tension control. Drives and
operating elements must be capable of being adjusted quickly and precisely to regulate web tension
and monitor machine performance.
Measuring amplifiers are an important part of the measuring chain. With cycle times from 0.5 ms, we
offer real-time data transmission to the machine’s master controller (or Programmable Logic Controller)
with the most common Ethernet and fieldbus interfaces, such as Profinet, EtherNet/IP and Ethercat.
Our latest-generation amplifiers are available in single and dual-channel (sum or individual signals of
two force sensors on the left and right of the measuring roller) models. Versions with higher input
sensitivity, as well as devices for potentially explosive atmospheres and other customer-specific
requirements, are available from stock.

How to select force measuring blocks for horizontal and vertical measurement
Force measuring blocks from FMS are available in horizontal or vertical measuring directions.
To select the right force sensor, we need to know the magnitude and direction of the measured
force. These depend on the wrap angle (web path around the idler roller), the actual web tension
and, if applicable, the weight of the roller.
Normally, force measuring blocks are mounted horizontally. This means that the contact surface of
the pillow block housing is aligned horizontally. From a design point of view, this is the simplest
solution and is therefore very common. In such a configuration, the weight force of the roller adds to
the web tension force.
FB – web tension
FG – weight (force) of the roller
FRes – resulting force from web tension FB
FV – vertical component of the resulting
force FRes
FH – horizontal component of the
resulting force FRes

Figure 1: Typical arrangement of web tension (blue) and force sensor (grey)

The use of horizontal force measuring blocks offers the advantage that they do not measure the
weight of the idler roller. They only measure the horizontally acting force component FH of the web
tension. This means that the force sensors can be somewhat smaller in size and can also measure

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the tension of the web more accurately, as the entire stroke/measuring range is available almost
exclusively for the web tension.
In rare cases, the wrap angle of the paper web around the measuring roll is symmetrical, so an
exactly vertical resulting force (force to be measured) occurs. This means that we usually obtain a
horizontal force component that we can use for measurement.
A typical application for a vertical measuring block would be if, for example, the force to be
measured acts almost or exactly vertically and therefore no or only a very small horizontal
component of the force to be measured is present.
In fact, the force measuring blocks can also be mounted in any installation position, e.g. with a 45°
inclination. However, this is usually avoided due to the increased design and manufacturing costs.

Figure 2: FMS-Calculator: Vertical measuring block, influence of weight force of the idler roller (blue bar)

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Figure 3: FMS-Calculator: Horizontal measuring block, without influence of the roller weight, identical size, smaller nominal
force

If a vertical measuring block is mounted horizontally (most common mounting), the measuring force
(FM) depends on the web tension (FB), the wrap angle and the weight force FG of the roller
(including pillow block housings and roller bearing).
The horizontal measuring block, on the other hand, only measures the horizontal component (FH) of
the web tension (FB), not the vertical force (FV). The measuring force (FMR, FRes) is only
dependent on the web tension (FB) and the wrap angle. As the weight force (tare) - the weight of the
idler roller - is not measured, it can be very large compared to the material tension without affecting
the accuracy of the measurement.
FMS-Calculator
We are the only company on the market to offer our customers an online tool that clearly illustrates
these complex relationships and helps with the selection and design of force sensors. It is available
free of charge at https://calculator.fms-technology.com

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Figure 4: Scheme of a Fourdrinier machine with typical measuring points for web tension and nip force

Figure 5: Horizontal and vertical measuring block

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Figure 6: PMGZ-series, paper production

Figure 7: UMGZ-series, paper production

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Figure 8: UMGZP-series, drop-in-replacement for Philips Block, recycling paper production

Conact information

FMS Force Measuring Systems

Norbert Schilling
Product Manager
 +41 44 852 80 79
 [email protected]
www.fms-technology.com