Tension Control Systems

Warner Tension Control Systems – Available from BIBUS Kft. Magyarország

 

BIBUS Kft. Magyarország offers a comprehensive range of Warner Electric tension control solutions, covering the TB, ATT, and MTB brake series, as well as TCS analog controllers and XCTRL/X2DRV digital units. These systems provide flexible and precise tension control across a torque range of 0.5 Nm to 1,000 Nm, and a diameter range of 0.5–10:1, from small-scale analog setups to high-accuracy digital regulation.
They are ideal for winding, laminating, labeling, and other winding/rewinding processes, where stable tension and precise control are essential.

 

Tension Control System Overview

 

Warner Electric’s tension control systems offer precise, scalable solutions for regulating web, foil, and reel tension in unwinding/rewinding machines, printing systems, and automated production lines.

 

1. Tension Brakes

• TB Series (Basic Tension Brakes)
  • 24 V DC, plate-type design
  • Torque range: 0.5–256 lb·ft (≈ 0.7–347 Nm)
  • Compact format with diameters from 1.7″ to 15.25″
• ATT Series (Advanced Technology Tension Brakes)
  • Designed for shaft-mounted applications
  • Torque range: 8–62 lb·ft (~10–84 Nm)
• MTB Series (Modular Tension Brakes)
  • Modular design with expansion capability
  • Diameter: 10″–20″, up to 750 lb·ft (~1,010 Nm)
  • Replaceable brake pads
  • Heat dissipation: up to 6 HP

 

2. Control Units

• TCS 220 Analog Controller
  • 48 V DC, variable current control
  • Output current: 0–270 mA for running, 270–500 mA for braking
  • Input via external potentiometer or signal source
  • Integrated PID control
• MCS 204 & MCS 203
  • 24 V DC modular control units
• MCS 204: manual/analog control
• MCS 203: automatic dancer arm control
  • Each can control 1–2 brakes
• XCTRL + X2DRV System
  • Digital closed-loop control
  • Feedback from dancer arm or load cell
  • Ensures precise and stable tension values

 

3. Key Features and Benefits

• Low backlash, highly precise and stable tension control, even during flying splice operations
• Analog (TCS 200/220) and digital (MCS 2000/XCTRL) PID control options
• Designed for up to 10:1 diameter range ratios
• Plug & play installation, easy to maintain
• Wear-free, thermally resistant components
• No regular maintenance required