Description

Sensor roller PD 30.. en

1. Safety 2
2. Function 2
2.1 Intended usage 2
2.2 Design 3
2.3 Operating principle 4
2.4 The measuring principle 4
2.5 Calculating the resultant web tension 4
2.6 Calculation examples 5
3. Assembly 6
4. Installation 6
5. Maintenance 7
6. Technical data 7

BEA--250204-EN-02
Sensor roller PD 30..

1. Safety
1.1 Explanation of symbols  jobs to be performed
important information and instructions
text sections requiring particular attention to assure the safe
operation of the PD 30.. sensor roller.

1.2 Description Keep this description in a safe place, accessible to personnel at all
times.

1.3 Operation All tasks specified in this description should be performed by quali-
fied or suitably instructed personnel only.
Sensor rollers are highly sensitive electronic measuring
equipment.
To set the parallelism to other rollers, force may only be exerted
on the sensor roller axle. Impact stress to the roller body could
damage the load cells inside the sensor roller.
Please ensure that no mechanical stress arises during assembly.
Mechanical stress could also affect the load cell function and, in
extreme cases, could lead to damage!

1.4 Safety instructions Never reach inbetween moving rollers.

Never touch the edges of moving webs.

2. Function
2.1 Intended usage
Web
E+L Sensor roller

Amplifier

The E+L sensor roller PD 30.. measures all radial forces effected by
a web on a sensor roller, in the measuring direction. The web should
wrap the sensor roller at angles between 60° and 180°. An amplifier
analyses the signals.

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 Sensor roller PD 30..

2.2 Design

Roller Load cell Axis Ball bearing

Load cell

Nominal width NB
Measuring element
Length of axis A

Basic diagram: cross-section of sensor
roller
E+L sensor rollers mainly consist of a roller with internal bearing and
with a fixed axle, of two load cells and two ball bearings. The load
cells are mounted on the axis and accommodate the ball bearings.
Each load cell has two measuring elements designed as dual flexible
beams to which the strain gauges are connected. The mechanical
stop protects the load cell against overload. The overload factor is 10
times the nominal measuring range.

2.2.1 Sensor roller PD 30..

option table

Type Nom. meas. range FN Ø Roller NB min NB max A min Ø Axle Thread
per roller
(kN) (mm) (mm) (mm) (mm) (mm)
PD 3008 0,2 0,4 1 80 300 1200 NB + 10 20 M 12
PD 3010 0,3 0,6 1,5 100 300 1800 NB + 10 20 M 12
PD 3012 0,3 0,6 1,5 120 400 2500 NB + 10 20 M 12
PD 3016 0,6 1,2 3 160 600 3000 NB + 10 40 M 16
PD 3020 0,6 1,2 3 200 600 3200 NB + 10 40 M 16

2.2.2 Roller surface option Surface index Surface

table 01 polished RA 3,2 (standard)
02 wrapped with rubber cork
03 finely sprayed with glass corundum RA 6,3, hard-anodised,
layer thickness 30 µm 450 HV
04 hard-anodised, layer thickness 30 µm 450 HV
05 spiralised left + right, pitch 40 mm, groove radius 6 mm,
slot depth 0,25 mm
13 coarsely blasted with glass corundum RA 11,5 - 15,
hard-anodised, layer thickness 30 µm 450 HV
20 spiralised left + right, pitch 40 mm, groove radius 6 mm,
slot depth 0,25 mm, hardslide-coated,
layer thickness 50 µm 450 HV

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Sensor roller PD 30..

2.3 Operating principle
Stabilized D.C. voltage from the amplifier supplies the full strain
gauge bridge in the load cells. Due to the influence of the web ten-
sion, a change in resistance in the strain gauges takes place, effect-
ing a deviation in the electrical output signal from the load cells. The
deviation is proportional to the web tension.
The load cell output signals can either be analyzed separately or the
arithmetic mean can be determined by parallel connection.

2.4 The measuring principle

Resultant web tension FR Influence of roller weight force FGR depending on

in direction of measurement direction of measurement

Measuring direction
Neutral horizontal vertical displaced
line
Web tension

Measuring
direction
horizontal γ

FG FG FG
Web tension
FGR = 0 FGR = FG FGR = FG x cos γ

F = Web tension FGR = Roller weight force components in measuring direction

F1, F2 = Web tension components γ = Angle between weight force and measuring direction
FR = Resultant web tension
FG = Roller weight force

The load cell measuring principle is based on the determination of

radially effective bearing forces from the roller, which is wrapped by a
web.
Only the web tension components F1 and F2 acting in the direction
of measurement of the sensor roller are relevant for measuring. The
resultant web tension FR for the sensor roller results from the sum of
both web tension components. The direction of measurement is indi-
cated on the type plate by arrows.
If the measuring direction deviates from the horizontal, the
force component FGR arising from the force of the weight FG
must be taken into account.

2.5 Calculating the resultant When calculating the resultant web tension FR please proceed as
web tension follows:
 Determine the angle of wrap of the web.
The web should wrap the sensor roller at an angle between 60°
and 180°. The aim is to achieve a wrapping angle of 90°.

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 Sensor roller PD 30..

 Determine the measuring direction and calculate the resultant web

tension FR (see chapter 2.6 calculation examples).
The aim is to achieve a horizontal measuring direction. When
this is the case, the roller weight is located in the neutral
zone and does not exert stress on the load cells.

2.6 Calculation examples

Resultant web tension with Resultant web tension with vertical measuring direction
horizontal measuring direction
Measuring
direction

Measuring
direction

Measuring
direction

F1 = F • cos α F1 = F • cos α F1 = F • cos α

F2 = F • cos β F2 = F • cos β F2 = F • cos β

FR = F1 + F2 FR = F1 + F2 + FG FR = F1 + F2 - FG

Resultant web tension with displaced measuring direction

Measuring
direction

F = Web tension
F1 = Web tension components
in measuring direction
F2 = Web tension components
in measuring direction
FG = Roller weight force
FGR= Roller weight force compo- Measuring
nents in measuring direction direction
FR = Resultant web tension
in measuring direction
α, β = Angle between F1 = F • cos α F1 = F • cos α
web tension direction F2 = F • cos β F2 = F • cos β
and measuring direction FGR = FG • cos γ FGR = FG • cos γ
γ = Angle between
weight force and FR = F1 + F2 + FGR FR = F1 + F2 - FGR
measuring direction

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Sensor roller PD 30..

3. Assembly Please observe the locally applicable and professional safety

and accident prevention regulations.
During assembly please observe the project or precalculated sen-
sor roller measuring direction (the arrows on the type plate of the
sensor roller indicate the direction of measurement).
Sensor rollers are highly sensitive electronic equipment.
To set the parallelism to other rollers, force may only be exerted
on the sensor roller axle. Impact stress to the roller body could
damage the load cells inside the sensor roller.
Please ensure that no mechanical stress arises during assembly.
Mechanical stress could also affect the load cell function and, in
extreme cases, could lead to damage!

4. Installation Please observe the locally applicable and professional safety

and accident prevention regulations.
 Run the electrical leads according to the attached wiring diagram
and observe the cross-section and shielding details.
 Please ensure that the insulation is not damaged and the leads
correctly secured and protected.
 The connection lead of the sensor roller should run separately
from interfering or power lines (e.g. mains of motor lines). It should
be connected directly to the web tension amplifier, that is without
intermediate terminals.
 Make sure that the shielding of the connection lead is connected
to the mass only at the side of the load tension measuring ampli-
fier.
The connection lead between load cell and web tension measur-
ing amplifier should be as short as possible. The maximum per-
missible length is 10 m.

4.1 Ground and frame  Please also observe the enclosed EMC specifications.
connections  Ensure that all ground and frame connections are run according to
the wiring diagrams.
All E+L components must be connected to the same frame poten-
tial as the whole machine.
Wiring which has not been provided by E+L must conform with
E+L cable specifications i.e. must be shielded so that all connec-
tions can be run in accordance with the wiring diagrams.

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 Sensor roller PD 30..

4.2 Static discharge When using the sensor rollers in production plants in which the
material to be processed (e.g. plastic sheets) causes strong static
discharge, take appropriate measures (ionization rods, ventilation
and grounding measures) to ensure that the discharge does not take
place via the sensor roller connection leads. The sensor roller and
downstream amplifier/controller could otherwise be damaged by this.

5. Maintenance Protect the sensor roller from heavy soiling and moisture
(protection class IP 50).

5.1 Ball bearings The smooth running deep-groove bearings in the sensor roller are
equipped with lifetime permanent lubrication. In cases of bearing
damage, we recommend that you send the sensor roller to E+L for
inspection and repair. Special tools are required for dismantling the
sensor roller.

5.2 Load cells If a defect should arise in one of the load cells, the sensor roller must
be replaced or sent to E+L for repair. Individual parts cannot be
replaced by the customer as the sensor roller requires recalibration
after repair.

6. Technical data Roller

Material Roller tube AlMgSi 0,5
Bearing deep-groove ball bearing with
locating and floating bearings
incl. labyrinth seal and
lubrication for life
Balance quality dynamically, precision-balanced
to VDI 2060
PD 3008, PD 3010, PD 3012 quality grade Q = 2,5
PD 3016, PD 3020 quality grade Q = 6,3
Concentricity <50 µm for NW = 1000 mm
Cylinder form <50 µm/m
max. speed
PD 3008 3600 min-1
PD 3010 3000 min-1

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 Erhardt + Leimer GmbH
Postfach 10 15 40
D-86136 Augsburg
Telephone (0821) 24 35-0
Telefax (0821) 24 35-6 66
Internet http://www.erhardt-leimer.com
E-mail info@erhardt-leimer.com

Load cell
Precision class 0,5
Nominal characteristic value 1 mV/V
(sensitivity)
Combined error <0,5 %
(Hysteresis/Non-linearity)
Characteristic value tolerance 0,2 %
Measuring principle full strain gauge bridge
Nominal strain gauge bridge
resistance 700 Ohm
Bridge supply voltage
Nominal value 10 V
Max. permissible value 14 V
Output voltage
Nominal range 0 to 10 mV (with nominal force
and a bridge supply voltage
of 10 V)
Max. range 0 to 18 mV (with 1,8 x nominal
force and a bridge supply
voltage of 10 V)
Nominal force FN see option table page 3
Max. utility load 1,2 to 1,8 FN
Mechanical stop 1,2 to 1,8 FN depending on type
Limit load 10 x FN
Nominal measuring path 0,05 to 0,15 mm depending
on type
Nominal temperature range - 10 to + 60 °C
Normal temperature range - 10 to + 70 °C
Storage temperature range - 30 to + 70 °C
Temperature coefficient
- of the characteristic value ±0,3 %/10 K
- of the zero signal ±0,3 %/10 K
Protection class IP 50
Max. permissible axial
transverse force 1 x FN
Connection cable 6 x 0,14 mm², 10 m long
Technical data subject to modification without notice