The Need for Constant Tension Devices
As a spool of material pays off, its diameter gradually decreases. Using a constant torque brake (Magnetic, Friction, Air, or other), the web tension on the material will increase as the diameter decreases. For some applications this is not a concern, however for others this poses a major problem.
Example: If a spool begins at 18″ diameter with 1lb of tension and ends at 3″ core size, the tension will reach 6lb by the time the spool is nearing empty.
Over the years, we have developed several solutions to this problem.
Electric Hysteresis Brakes with PowerPro24
Our latest, most flexible, and most accurate option for constant payoff is our PowerPro24 tension controlling power supply along with our line of electric hysteresis brakes. This solution offers the ultimate in tension control, after inital setup you can put any spool within the design parameters on the shaft and the system will automatically detect and adjust for the spool. This is a great solution if you use a variety of spools, sometimes need to run half-empty spools, or you want the ability to easily change tension with a direct keypad entry.
Follower Arm Constant Tension Brakes
These brakes create a constant web tension by mechanically adjusting the torque setting based on spool diameter. The brake is then coupled to the spool through a timing pulley. We offer three sizes of this style brake. The delrin roller rests lightly on the surface of the material, tensioning is not done through this roller it is only used to follow the diameter of the spool. This brake offers a great way to achieve constant tension, but has limited flexibility as the geometry and pulley ratio are selected to give a specific tension on a specific spool. This style brake requires no electricity for operation.
Surface Mount Constant Tension Brakes
These brakes create a constant web tension by tensioning the spool at the material surface. Because the torque is acting on the fixed diameter body of the brake, the radius is no longer changing and thus tension remains constant. We offer two sizes of this style brake. The assembly is spring loaded and the body of the brake has a urethane sleeve that rides on the surface of the material. This style brake requires no electricity for operation.