Tension sensors, indicators and amplifiers are components dedicated to integrating tension measuring systems into industrial machinery and into custom solutions. They comprise strain-gauge load cells dimensioned for tension measurement (S-beam, button and pancake geometries), three-roller transducers for integration into machines, digital indicators with industrial interfaces, and signal amplifiers for high-dynamic DAQ applications. They are the technical core of OEM stationary tension meters, of custom test benches, of structural monitoring systems and of special applications for which no standard solution is available on the market.
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Load cells for tension
The strain-gauge cells most used for tension measurement are: S-beam geometry (for tensile measurement on wires and belts, ranges from cN to kN); pin geometry (for integration into the movable rollers of three-roller tension meters, measuring the lateral force on the pin); button or pancake geometry (for weighing applications and for tension on short cords and heavy objects); and flange cells (for integration into the shafts of industrial machines, measuring torsion and axial force simultaneously). The choice of geometry depends on the mechanical configuration of the application.
Industrial indicators
Industrial indicators for tension systems combine: transducer supply with a stabilised, isolated voltage; signal amplification to industrial levels (4-20 mA, 0-10 V, digital outputs); anti-noise filtering; linearisation functions; automatic calibration (zero, span); setpoint functions with relay output for ON/OFF control; internal data logging; and an LCD/LED display for monitoring from the control room. Standard digital interfaces (RS-485 Modbus, Profibus, Profinet, CAN, EtherCAT) allow integration with industrial PLCs and SCADA systems for automatic process control.
DAQ amplifiers
For high-dynamic DAQ applications (materials testing, R&D, structural monitoring), high-class amplifiers provide: low noise for precision measurement (resolution up to 24 bit); wide bandwidth (up to tens of kHz); multi-channel synchronisation for simultaneous acquisition; automatic calibration with shunt-cal; and high-speed interfaces (1 Gbps Ethernet, USB 3.0, PCI Express). They are used in measuring chains for laboratory test benches, where force, tension, position and acceleration have to be acquired simultaneously with high timing accuracy.
Custom applications
Integrating these components makes custom solutions possible: OEM stationary tension meters dimensioned for a particular manufacturer’s machines; custom test benches for high-tension materials testing; structural monitoring systems for civil works (bridges, cranes, antennas); process control systems for special production lines; calibration benches for other sensors; and equipment for university research and industrial laboratories. The flexibility of the components allows the solution to be tailored to the specific needs of the application, with optimized cost and performance.
Calibration standards
Calibration of tension measuring components follows the standards for force instruments: ISO 376 (calibration of load cells for testing machines); ISO 7500-1 (metrological verification of universal testing machines, applicable to custom test benches). Primary calibration is carried out with certified masses or with master cells calibrated to ISO 17025 by accredited laboratories. Periodic calibration is recommended every 12 months for high-accuracy applications and every 24 months for standard applications.
Selection criteria
The choice of components depends on the requirements of the application: force and tension range, accuracy, bandwidth, environmental conditions, interfaces required, and cost. Sizing the sensor, the amplifier and the DAQ together is recommended, in order to obtain optimum performance. For complex projects it is advisable to work with suppliers that offer engineering services alongside the supply of components.
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