ABB PFTL101B-10.0kN Pressductor Pillowblock Load Cells

I. Overview

II. Core Functional Features

1. High-Precision Tension Measurement and Real-Time Output

• High Measurement Precision: The measurement accuracy reaches ±0.1% FS (Full Scale), with a linear error ≤0.05% FS and a hysteresis error ≤0.03% FS. It can accurately capture subtle tension changes (e.g., a minimum resolution of 0.1N within the 10kN range). For example, in a film production line, when the tension fluctuates from 5kN to 5.05kN, the sensor can output a current signal in real time from 12mA (corresponding to 5kN) to 12.2mA (corresponding to 5.05kN), with an error ≤0.002mA, providing a precise adjustment basis for the controller.

• Wide Range Adaptability: It has a rated measurement range of 10.0kN and an overload capacity of 150% FS (short-term) / 120% FS (long-term), which can withstand instantaneous tension impacts during production (such as tension peaks when coil joints pass through) and prevent sensor damage. At the same time, it supports the measurement of any tension value within the range, and can adapt to the tension requirements of different materials and processes without replacing the sensor (e.g., a paper production line can measure 1-8kN tension, and a metal foil production line can measure 3-10kN tension).

• Real-Time Signal Output: It adopts the 4-20mA DC standard analog signal output, with a signal response time ≤1ms, which can follow tension changes in real time and transmit tension data without delay. For example, in high-speed cable stranding production, where the cable tension change frequency reaches 10Hz, the sensor can still respond quickly and output a stable signal, ensuring the controller adjusts the traction speed in a timely manner to avoid uneven cable stretching.

2. Environmental Adaptability and Anti-Interference Design

• Strong Protection Performance: The housing is made of 316L stainless steel, polished and passivated, with excellent corrosion resistance. It can be used in scenarios such as metallurgical workshops (with metal dust and coolant splashes) and papermaking workshops (high humidity). The IP67 protection rating means the sensor can be briefly immersed in water (1m depth for 30 minutes), preventing moisture from entering the internal circuit and causing malfunctions.

• Temperature Compensation and Stable Operation: Equipped with a high-precision temperature compensation circuit (compensation range: -20℃~80℃), it can offset the impact of temperature changes on measurement accuracy. For example, in a low-temperature environment of -10℃, the measurement error only increases by ≤0.02% FS, which is much lower than the 0.1% FS error of sensors without compensation, ensuring measurement stability in high and low-temperature environments.

• Electromagnetic Anti-Interference Capability: The signal conditioning circuit adopts differential amplification and EMC filtering design, complying with the IEC 61000-6-2 industrial anti-interference standard. It provides electrostatic discharge (ESD) protection of ±8kV (air discharge) / ±4kV (contact discharge) and electrical fast transient (EFT) protection of ±2kV, which can resist high-frequency electromagnetic interference generated by frequency converters and motors near the production line, avoiding signal distortion (e.g., 4-20mA signal fluctuation ≤0.01mA).

3. Flexible Installation and Convenient Calibration

• Adaptability to Multiple Installation Methods: It supports various mechanical installation structures such as flange mounting, pin mounting, and suspension mounting, which can be flexibly selected according to the installation positions of tension rollers and guide rollers in the production line. For example, in the winding section of a papermaking machine, flange mounting is used to fix the sensor next to the winding roller bearing seat to directly measure the winding tension; in a cable traction production line, suspension mounting is used to hoist the sensor above the tension roller to adapt to space-constrained scenarios.

• Standardized Signal Interface: It uses an M12 circular connector or terminal junction box as the signal output interface, with simple wiring (four-core wires: positive power supply, negative power supply, positive signal, negative signal). It can be quickly connected to PLCs and tension controllers, reducing on-site wiring time. The interface has an anti-misinsertion design to avoid circuit damage caused by reverse connection of positive and negative poles.

• Convenient Calibration Function: It supports on-site zero calibration and range calibration, which can be completed without disassembling the sensor. Through ABB's dedicated calibration software or the controller's built-in calibration function, inputting a known tension value (e.g., applying a 5kN standard weight using the weight hanging method), the sensor can automatically correct measurement deviations. The calibration process takes ≤5 minutes, significantly reducing maintenance costs. For example, during production line shutdown maintenance, maintenance personnel can initiate calibration through the PLC operation interface without professional calibration equipment.

4. Long-Term Stable Operation and Fault Self-Diagnosis

• High-Reliability Structure: The strain gauges are bonded to the elastic body using a high-temperature curing process. The elastic body is made of high-strength alloy steel (40CrNiMoA), which has an excellent fatigue life (capable of withstanding 10 million full-scale cyclic loads). After long-term use (≥5 years), the measurement accuracy attenuation is ≤0.05% FS, reducing the frequency of sensor replacement.

• Fault Self-Diagnosis: It has a built-in circuit fault monitoring function. If overvoltage (>30V DC), undervoltage (<18V DC) of the power supply, or abnormality of the internal signal conditioning circuit is detected, the sensor will output a fault signal (e.g., current fixed at 22mA or 0mA, depending on the model) and trigger an alarm through the PLC or controller. This facilitates maintenance personnel to quickly locate faults (such as checking power supply voltage or replacing the sensor) and avoid production accidents caused by sensor failures.

III. Technical Parameters

1. Electrical Parameters

2. Mechanical and Environmental Parameters

3. Reliability Parameters

• Fatigue Life: ≥10 million full-scale cycles (in accordance with ISO 3808 standard);

• Mean Time Between Failures (MTBF): ≥50,000 hours;

• Material Certification: The elastic body material complies with EN 10088-3 standard, and the housing complies with ASTM A240 standard.

IV. Working Principle

1. Tension Force Application Stage: When coiled materials (such as steel plates and paper) in the production line pass through the tension roller, the tension value is transmitted to the sensor's elastic body (high-strength alloy steel). The elastic body undergoes slight elastic deformation under the action of tension (e.g., a deformation of approximately 0.1mm under a 10kN tension).

2. Strain Sensing Stage: Four high-precision metal strain gauges bonded to the surface of the elastic body (forming a Wheatstone bridge) produce resistance changes as the elastic body deforms—tensile strain gauges show increased resistance, while compressive strain gauges show decreased resistance. This breaks the bridge balance, outputting a weak voltage signal (in the mV level).

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4. Signal Conditioning Stage: The sensor's built-in signal conditioning circuit (including an amplifier, filter, and temperature compensator) amplifies the weak voltage signal (to the V level), filters out high-frequency noise, and performs temperature compensation (to offset the impact of temperature on resistance), converting it into a voltage signal linearly related to the tension value.

5. Signal Conversion and Output Stage: The conditioned voltage signal is converted into a 4-20mA DC standard industrial signal via a D/A converter (e.g., 4mA corresponding to 0kN and 20mA corresponding to 10kN), which is then output to the PLC, DCS, or tension controller through the signal interface.

6. Closed-Loop Control Stage: The controller receives the 4-20mA signal, calculates the current tension value, and compares it with the set tension value. If there is a deviation (e.g., actual tension of 5.2kN > set value of 5kN), it drives the actuator (such as adjusting the traction speed via a frequency converter or adjusting the tension roller pressure via an air cylinder) until the tension returns to the set value, forming a closed-loop tension control.