ABB ABB PFCL201C 3BSE023409R20 Pressductor PillowBlock Load Cells

I. Overview

II. Functional Features

1. Medium-Range High-Precision Tension Measurement

• Ultra-High Measurement Precision: The measurement accuracy reaches ±0.08% FS (Full Scale), with a linear error ≤ 0.04% FS and a hysteresis error ≤ 0.03% FS. The minimum resolution within the 10.0kN range is 0.1N. For example, in a rolling production line for medium and heavy steel plates (thickness 5-10mm), when the steel plate tension fluctuates from 6kN to 6.2kN, the sensor can output a current signal in real time from 13.6mA (corresponding to 6kN) to 14.08mA (corresponding to 6.2kN), with an error ≤ 0.008mA. This provides an accurate adjustment basis for the controller, preventing thickness deviations (≤ 0.05mm) of the steel plate caused by uneven tension.

• High Rigidity and Impact Resistance: The elastic body is made of 40CrNiMoA high-strength alloy steel, subjected to quenching and tempering treatment (hardness HRC30-35), with rigidity increased by 30% compared to conventional sensors. It can withstand continuous pressure and instantaneous impacts from medium-load coiled materials (such as 12kN instantaneous tension when coil joints pass through). After long-term use (≥ 6 years), the elastic body shows no plastic deformation, and the measurement accuracy attenuation is ≤ 0.05% FS.

• Stable Output Across Wide Temperature Range: It uses low-temperature-drift strain gauges (temperature coefficient ≤ 0.0003% FS/℃) and a two-stage temperature compensation circuit. Within the operating temperature range of -20℃~80℃, the temperature drift is ≤ 0.001% FS/℃. For instance, in a metallurgical workshop with high summer temperatures (50℃) and low winter temperatures (-10℃), the change in measurement error is only ≤ 0.08% FS, much lower than the 0.15% FS temperature drift of conventional medium-range sensors, ensuring measurement stability across the entire temperature range.

2. Reinforced Structure and Environmental Adaptability

• IP67 Protection and Corrosion Resistance: The housing is made of 316L stainless steel, and after passivation treatment, its surface salt spray resistance meets the ASTM B117 standard (no corrosion for 1000 hours). The IP67 protection rating prevents coolant splashes in metallurgical workshops, moisture intrusion in papermaking workshops, and even short-term water immersion (30 minutes at 1m water depth), avoiding short circuits in internal circuits or component corrosion.

• Vibration and Impact Resistance: The structural design complies with the IEC 60068-2-6 vibration standard (10-2000Hz, acceleration 10g) and the IEC 60068-2-27 impact standard (50g, 11ms). It can adapt to equipment vibrations in medium and heavy plate production lines (such as rolling mill vibration frequency of 50Hz), with sensor output signal fluctuation ≤ 0.01mA, avoiding tension misjudgment caused by vibration.

• Overload Protection and Self-Protection: It has a short-term overload capacity of 150% FS (15kN) and a long-term overload capacity of 120% FS (12kN). A built-in overload protection circuit automatically cuts off the high-gain amplifier circuit and outputs a fixed fault signal (22mA) when the tension exceeds 15kN, while locking the measured value to prevent overload damage to the elastic body. For example, in power cable traction, if the cable jams and causes the tension to rise sharply to 14kN, the sensor can withstand it normally and issue an alarm, avoiding permanent damage.

3. Intelligent Diagnosis and Multi-Mode Communication

• Full-Link Fault Diagnosis: It has three built-in functions: power supply monitoring, strain gauge status detection, and communication link diagnosis. It can real-time detect faults such as power overvoltage (> 30V DC), undervoltage (<18V DC), strain gauge open/short circuit, and RS485 communication interruption. While outputting a fault signal, it uploads fault codes (e.g., "E02: Strain Gauge Short Circuit", "E05: PROFINET Communication Interruption") through the digital interface. Maintenance personnel can quickly locate faults via upper computer software, reducing troubleshooting time by 60%.

• Multi-Signal Output and Connectivity: It supports three signal output modes: ① 4-20mA DC analog signal (compatible with traditional control systems); ② RS485 digital signal (Modbus RTU protocol, transmission rate 9600-115200bps, capable of transmitting tension values, fault codes, and temperature compensation parameters); ③ Optional PROFINET industrial Ethernet (transmission rate 100Mbps, supporting high-speed upload of real-time tension data and diagnostic information). For example, in an intelligent papermaking plant, the sensor connects to the factory's industrial Internet platform via PROFINET to upload kraft paper winding tension data in real time, allowing the platform to remotely monitor tension trends and predict maintenance needs.

• Remote Parameter Configuration: Through RS485 or PROFINET interfaces, parameters such as sensor sampling rate (adjustable 50Hz-500Hz), filter bandwidth (10Hz-200Hz), and fault thresholds (e.g., overload alarm threshold of 12kN) can be configured remotely without on-site sensor disassembly. This adapts to the maintenance needs of medium-load production lines for "fewer shutdowns and faster adjustments". For example, in tire tread coil production, when changing coil specifications, maintenance personnel can adjust the tension measurement range via remote configuration without shutdown calibration.

4. Flexible Installation and Convenient Maintenance

• Adaptability to Multiple Installation Methods: It supports three installation methods—flange mounting, pin mounting, and double-ear suspension mounting—to adapt to different mechanical structures of medium-load tension rollers and winders. For example, at the exit of a medium and heavy plate rolling mill, flange mounting is used to fix the sensor next to the tension roller bearing seat for direct measurement of steel plate tension; on cable traction equipment, double-ear suspension mounting is used to hoist the sensor above the traction roller, adapting to high-altitude installation scenarios.

• Standardized Interface and Anti-Misinsertion: It uses an M12 circular connector (5-core, with anti-misinsertion key design). The wiring distinguishes between power supply, analog signals, and digital signals to avoid circuit damage caused by reverse connection of positive and negative poles or signal confusion. The connector has an IP67 protection rating, consistent with the sensor body, ensuring overall protection performance.

• On-Site Rapid Calibration: It supports three calibration modes—"zero calibration", "two-point calibration", and "remote calibration": Zero calibration can be completed by short-pressing the button on the sensor side for 3 seconds (under no-load condition); two-point calibration requires inputting standard tension values (e.g., hanging 5kN and 10kN weights) via ABB calibration software; remote calibration can issue calibration commands through the PROFINET interface. The calibration process takes ≤ 5 minutes and can be completed by production line operators without the need for a professional calibration team.

III. Technical Parameters

1. Electrical Parameters

2. Mechanical and Environmental Parameters

3. Reliability and Certification Parameters

• Fatigue Life: ≥ 12 million full-scale cycles (in accordance with ISO 3808 medium-load standard);

• Mean Time Between Failures (MTBF): ≥ 60,000 hours;

• Certification Standards: CE Certification (EN 61326-1), Optional ATEX Certification (for explosive environments), RoHS 2.0 Certification;

• Material Certification: 316L stainless steel complies with ASTM A240 standard; Elastic body complies with EN 10083-3 standard.

IV. Working Principle

1. Medium Tension Force Application Stage: When medium-load coiled materials (e.g., medium and heavy steel plates, kraft paper) pass through the tension roller, the 10kN-level tension is transmitted to the sensor’s elastic body (40CrNiMoA alloy steel). The elastic body undergoes slight elastic deformation under tension (approximately 0.08mm deformation under 10kN tension). Although the deformation is small, the rigidity is sufficient to avoid plastic deformation risks.

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3. Strain Sensing Stage: Four high-precision metal strain gauges are bonded to the surface of the elastic body (forming a full-bridge circuit to improve signal sensitivity). As the elastic body deforms, the strain gauges produce resistance changes—tensile strain gauges show increased resistance, while compressive strain gauges show decreased resistance. The full-bridge circuit outputs a weak mV-level voltage signal (the signal amplitude is twice that of a half-bridge circuit, with stronger anti-interference capability).

4. Intelligent Signal Processing Stage: The built-in intelligent signal processing unit processes the mV-level signal: ① Amplifies the signal to the V level via a low-noise amplifier; ② Uses a 200Hz low-pass filter circuit to eliminate vibration noise from medium-load equipment (e.g., rolling mill vibration); ③ Uses a two-stage temperature compensation circuit to offset the impact of temperature on the elastic body and strain gauges; ④ A microprocessor performs linear calibration and fault judgment on the signal to generate accurate tension data and status information.

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6. Multi-Mode Signal Output Stage: The processed tension data is output in three ways: ① Converted to a 4-20mA DC analog signal via a 16-bit D/A converter (4mA corresponding to 0kN, 20mA corresponding to 10kN); ② Outputs digital tension values and fault codes through the RS485 interface; ③ Uploads real-time data to the industrial Internet platform at high speed via the optional PROFINET interface.

7. Closed-Loop Control Stage: The controller (e.g., ABB AC500 PLC) receives the tension data and compares the actual value with the set value (e.g., 8kN set tension for medium and heavy plates). If the actual tension (8.5kN) is greater than the set value, it drives the actuator (e.g., adjusting the winding speed via a frequency converter, adjusting the tension roller pressure via a hydraulic cylinder) to reduce the tension; if the actual tension (7.5kN) is less than the set value, it increases the tension. This ensures that the tension of the medium-load coiled material is stabilized within ±0.04kN, avoiding damage to materials or equipment.