Description B

Sensor roller PD 40.. en

1. Safety 2
2. Function 2
2.1 Intended usage 2
2.2 Design 3
2.3 Operating principle 3
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--250450-EN-03
Sensor roller PD 40..

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 40.. 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.
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 40.. 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.

B page 2
 Sensor roller PD 40..

2.2 Design

Measuring direction
+ -

D
50 NB

The sensor roller consists of a roller with rigid axis and two integrated
load cells. These load cells are fitted onto the axis and support the
ball bearings.
The measuring elements come as bi-directional strips. They support
the strain gauges which are interconnected and thus form a measur-
ing bridge. A mechanical stop protects the load cells from overload.
The overload factor is 10 times the nominal measuring range.

2.2.1 Sensor roller PD 40 Type ø Roller NB min NB max L Nom. measuring range FN
option table (mm) (mm) (mm) (mm) per roller (N)
PD 4006 60 150 300 NB+50 50 100 200

PD 4006 80 200 400 NB+50 100 200 400

PD 4010 100 250 500 NB+50 100 200 400
PD 4012 120 400 600 NB+50+3,5 200 400 600

2.2.2 Roller surface option Surface index Surface

table 01 polished RA 3,2 (standard)
03 corundum blasted RA 6.3, hard-anodised,
layer thickness 30 µm 450 HV
04 hard-anodised, layer thickness 30 µm 450 HV
13 corundum blasted RA 10.0 - 15.0, hard-anodised,
layer thickness 30 µm 450 HV

2.3 Operating principle
Stabilised d.c. voltage from the amplifier supplies the full strain gauge
bridge in the load cells. Due to the influence of the web tension, a
change in resistance in the strain gauges takes place, effecting a
deviation in the electrical output signal from the load cells. The devia-
tion is proportional to the web tension.
The load cell output signals can either be analysed separately or the
arithmetic mean can be determined by parallel connection.

B page 3
Sensor roller PD 40..

2.4 The measuring principle

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

in direction of measurement direction of measurement

Neutral Measuring direction

line horizontal vertical displaced
Web tension

Measuring
direction
horizontal γ

FG FG FG

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

F = Web tension FG = Roller weight force

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

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 fol-
web tension lows:
 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°.
 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.

B page 4
 Sensor roller PD 40..

2.6 Calculation examples

Resultant web tension with Resultant web tension with

horizontal measuring direction vertical 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

Preferred direction Resultant web tension with displaced measuring direction

Measuring direction

Measuring
direction

Measuring direction

FR = F1 F1 = F • cos α F1 = F • cos α
F2 = F • cos β F2 = F • cos β
FGR = FG • cos γ FGR = FG • cos γ
FR = F1 + F2 + FGR FR = F1 + F2 - FGR

F = Web tension FG = Roller weight force α, β= Angle between web tension

F1 = Web tension components in FGR= Roller weight force components direction and measuring direction
measuring direction in measuring direction γ = Resultant web tension in
F2 = Web tension components in FR = Resultant web tension in measuring direction
measuring direction measuring direction

B page 5
Sensor roller PD 40..

3. Assembly Please observe the locally applicable and professional safety

and accident prevention regulations.
During assembly please observe the measuring direction of the
sensor roller. This direction is determined during project planning
or precalculated (arrows on the type plate of the sensor roller indi-
cate the direction of measurement).
Sensor rollers are highly sensitive electronic equipment.
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!

Measuring direction
+ -

D
50 NB

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 mesuring amplifier.
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.

B page 6
 Sensor roller PD 40..

All E+L components must be connected to the same frame poten-

tial as the whole machine.
Cables which have 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.

4.2 Static discharge When using the sensor rollers in production plants in which the ma-
terial to be processed (e.g. plastic sheets) causes strong static dis-
charge, take appropriate measures (ionisation rods, ventilation and
grounding measures) to ensure that the discharge does not take
place via the sensor roller connection leads. Otherwise this could
damage the sensor roller and downstream amplifier/controller.

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.

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 re-
placed by the customer as the sensor roller requires recalibration
after repair.

6. Technical Roller
Material Roller tube ENAW-6060T66 (AlMgSi 0,5)
data Bearing pherical ball bearing with
locating and floating bearings
inclusive labyrinth seal and
lubrication for life
Balance quality - quality grade G = 2,5 (standard)
(dynamically, precision-balanced - quality grade G = 1,0 (optional)
to VDI 2060)
Concentricity < 50 µm
Cylinder form < 50 µm
Max. web speed
with balance quality G = 2,5 450 m/min
with balance quality G = 1 600 m/min
Max. web speed PD 4012
with balance quality G = 1 900 m/min for 600 N

B page 7
 Erhardt + Leimer GmbH
Postfach 10 15 40
D-86136 Augsburg
Telefon (0821) 24 35-0
Telefax (0821) 24 35-6 66
Internet http://www.erhardt-leimer.com
E-mail info@erhardt-leimer.com

Max. flection
with max. nomin. measuring force max. per 100 mm nomin. width
PD 4006 200 N 0,16 mm
PD 4008 400 N 0,21 mm
PD 4010 400 N 0,11 mm
PD 4012 600 N 0,08 mm
Roller weight
PD 4006, NB 150 mm, 1,43 kg for each 50 mm increase 0,23 kg
PD 4008, NB 200 mm, 3,8 kg for each 50 mm increase 0,4 kg
PD 4010, NB 250 mm, 6,6 kg for each 50 mm increase 0,72 kg
PD 4012, NB 400 mm, 17,32 kg for each 50 mm increase 2,21 kg
Assembly flange mounting - with centered thread
(centering shoulder available) - with 4 bores

Load cell
Precision class 1
Nominal characterisitc value 1 mV/V (sensitivity)
Combined error
(Hysteresis/Non-linearity) <1%
Characteristic value tolerance 0,2 %
Measuring principle full strain gauge bridge
Nominal strain gauge
bridge resistance 700 ohms
Bridge supply voltage
Nominal value 10 V
Max. permissible value 14 V
Output voltage
Nominal range 0 to 10 mV (with nomin. force and
a bridge supply voltage of 10 V)
Max. range 0 to 18 mV (with 1,8 x nomin. force
and a bridge supply volt. of 10 V)
Nominal force FN see option table page 3
Mechanical stop 1.2 to 1.8 FN dep. on the type
Max. utility force 1.2 to 1.8 FN
Limit force 10x FN
Nominal measuring path 0,15 to 0,25 mm dep. on the type
Nominal temperature range - 10 to + 60 °C
Operational temperature range - 10 to + 70 °C
Storage temperature range - 30 to + 90 °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 1x FN
Connection cable (plug-in type) 6 x 0,14 mm2, 5 m/10 m long
Technical data subject to modification without notice