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The ABB PFTL201D-100KN 3BSE008922R0100 is a high-performance, high-precision tension/force measuring sensor, primarily positioned as a core component for the accurate detection and real-time monitoring of strip tension and load force in industrial scenarios. It is custom-designed to meet the demands for highly reliable and high-precision force measurement in industrial automation systems. Integrating ABB's proprietary magnetoelastic sensing core technology with advanced digital signal processing technology, this sensor stably enables precise force measurement within the 0-100KN range, along with real-time data feedback and signal conversion. Boasting high precision, high overload resistance, strong anti-interference capability and flexible compatibility, it is widely applied in papermaking, steel, textile, material testing, hoisting equipment and other fields. It provides accurate and reliable measurement support for production process control, quality assurance and the safe operation of equipment, with genuine factory quality assurance and comprehensive adaptability to industrial systems, making it a classic model in ABB's industrial measurement product line.
I. Technical Parameters
Adopting a standardized industrial design that balances measurement accuracy, environmental adaptability and scenario compatibility, the core technical parameters of the sensor are integrated from multiple sources as follows, in line with the actual industrial measurement requirements to ensure precise data and stable operation:
Measurement Performance Parameters: The rated load (measuring range) is 100KN (22500lbs equivalent), with an extended load capacity of up to 150KN (33750lbs), meeting the measurement needs of medium and large force values and strip tension. The measurement accuracy reaches ±0.5% of the full scale, featuring low error and excellent repeatability to accurately capture subtle changes in load and tension. It adopts ABB's proprietary Pressductor® magnetoelastic sensing principle, which measures force by utilizing the characteristic of magnetic materials whose magnetic permeability changes under mechanical force. Equipped with a dedicated internal induction coil, it accurately senses potential changes and converts them into corresponding electrical signals, enabling non-contact measurement without physical displacement. It combines high sensitivity with an extremely strong overload resistance capacity — the overload capacity in the measuring (vertical) direction is up to 1000KN (225000lbs), and the transverse (horizontal) overload capacity is 500KN (112500lbs). It has no built-in load cycle limit and a long service life. The deflection is 0.05mm (2.0/1000 inch) and the spring constant is 2000KN/mm (11440×1000lbs/inch), with excellent rigidity suitable for high-stability measurement scenarios.
Power Supply and Signal Parameters: The power input supports a standard industrial power supply of AC 100-240V, 50/60Hz, adapting to industrial power supply systems in different regions without the need for additional dedicated power supplies. The output signals support mV/V analog signals, digital signals and current signals, and it is also equipped with USB/RS232 data transmission interfaces. The signal transmission method can be flexibly selected according to actual needs, facilitating seamless connection with data acquisition equipment, PLCs, controllers and industrial automation systems to realize real-time transmission, remote monitoring and subsequent processing of measurement data. The signal is a high-power, low-impedance AC signal with extremely strong resistance to electromagnetic interference and ground faults, suitable for complex industrial electrical environments.
Environmental Adaptation Parameters: The operating temperature range covers -20°C to 70°C, adapting to various complex temperature scenarios such as high-temperature industrial workshops and outdoor environments for long-term stable operation. The protection rating reaches IP65 (for the enclosed installation version), with excellent dust and water resistance to withstand erosion by dust and water vapor in industrial sites. It also supports the standard rail-mounted version to meet the installation requirements of different environments. Made of stainless steel (with corrosion resistance close to AISI 304), it has good corrosion resistance and is suitable for harsh industrial scenarios with high dust and humidity such as papermaking and chemical engineering. It complies with EMC standards and can resist industrial electromagnetic interference without additional protective enclosures.
Structural and Installation Parameters: It supports two installation methods — standard rail mounting and enclosed mounting for harsh environments, which can be flexibly selected according to on-site space and environmental conditions. Adopting a modular and compact design, the control unit is equipped with a pluggable screw terminal block at the bottom for convenient wiring and maintenance, and a built-in cable shielding grounding point to further enhance anti-interference capability. The overall structure is robust, adapting to the integrated installation requirements of industrial equipment. It can be directly installed at key measurement points such as strip production lines, hoisting equipment and test fixtures without complex installation and debugging procedures.
Additional Function Parameters: Equipped with a 2×16-bit multilingual digital display and function keys, it can intuitively display sum signals, difference signals or signals of each pressure head, facilitating parameter setting and status checking of the measurement system. It supports switching between multiple units (N, kN, MN, kp, t, lb, T) to adapt to the measurement habits of different regions and industries. Built-in self-diagnostic test system (including sensor testing) and simulation function enable quick fault troubleshooting and system integration checking, reducing maintenance difficulty. The filtering time can be adjusted within the range of 1-2000ms, with preset standard measurement modes and a built-in pressure head table. Setting parameters can be imported and exported via PC, supporting remote access and control.
II. Features and Advantages
Proprietary Sensing Technology for Accurate and Reliable Measurement: Adopting ABB's patented Pressductor® magnetoelastic sensing technology, it realizes force measurement based on the magnetoelastic effect without physical displacement or deformation, combining high sensitivity and high stability with a measurement accuracy of ±0.5% of the full scale and excellent repeatability. The high-power, low-impedance AC signal design features extremely strong resistance to electromagnetic interference and ground faults, enabling stable data transmission in complex industrial electrical environments, avoiding signal loss or mistransmission and ensuring the reliability of measurement data.
Extreme Overload Resistance and Long Service Life: It has an exceptional overload resistance capacity, with a measuring direction overload capacity of up to 1000KN and a transverse overload capacity of 500KN, far exceeding conventional force measuring sensors. It can effectively withstand instantaneous impact forces in industrial scenarios to avoid sensor damage. With no built-in load cycle limit, combined with stainless steel corrosion-resistant material and industrial-grade electronic devices, it has a long service life, can adapt to the requirements of long-term continuous industrial operation, and reduce the frequency of equipment replacement and maintenance costs.
Wide Scenario Adaptability and Flexible Installation: Supporting two installation methods of rail mounting and enclosed mounting, with an IP65 protection rating, corrosion and high temperature resistance, it is suitable for various complex industrial scenarios such as papermaking, steel, textile, hoisting and material testing. The standardized power supply and signal interfaces enable seamless connection with various PLCs, controllers and data acquisition equipment without additional adaptation modules. It also supports multi-unit switching and flexible parameter configuration to adapt to the measurement needs of different industries.
Easy Operation and Efficient O&M: Equipped with a multilingual digital display and function keys, it features intuitive and convenient parameter setting and status checking. The built-in self-diagnostic system and simulation function enable quick fault troubleshooting and system integration verification, reducing maintenance difficulty. The pluggable screw terminal block and modular design facilitate wiring, maintenance and replacement. It supports remote import and export of parameters via PC and remote control, further improving O&M efficiency and reducing downtime losses.
High Compatibility and Easy Integration: Adaptable to ABB and other brands of industrial automation systems, it supports a variety of signal transmission methods and communication interfaces, and can be easily integrated into existing production lines without large-scale transformation of the original system. With built-in preset standard measurement modes and a pressure head table, users can complete setup and precise measurement only by following step-by-step menu operations, greatly reducing integration and debugging costs.
III. Application Fields
With its high-precision measurement capability, extreme overload resistance and wide scenario adaptability, the sensor is widely applied in industrial tension measurement, load detection, material testing and other fields, especially suitable for scenarios with high requirements for measurement accuracy, equipment stability and environmental adaptability, including:
Strip Processing Field: Papermaking industry (tension measurement of wire and felt in paper machines), steel industry (tension monitoring in the strip steel production process), textile industry (tension detection of textile threads). By accurately measuring strip tension, it optimizes the production process, avoids strip breakage, wrinkling or tensile deformation, and ensures product quality and production continuity.
Material Testing Field: Suitable for material tensile and compressive strength testing, automotive component load testing, and bearing capacity testing of construction and civil engineering structures. It can accurately capture force changes during the testing process, providing reliable data support for R&D and quality control, and is an ideal measuring device for laboratories and third-party testing institutions.
Hoisting and Lifting Field: Used for measuring the load of hoisted goods in cranes, hoists and other equipment, it monitors the hoisting weight in real time, avoids overloading operation, prevents safety risks, and ensures the safety of personnel and equipment, suitable for industrial hoisting, port loading and unloading and other scenarios.
Industrial Automation Field: Load and tension measurement in automated production lines, batching systems, weighing equipment, presses and other scenarios to achieve precise production process control and quality monitoring. It also adapts to the relevant force measurement needs of biomass power generation, fermentation and other industries, helping to improve production efficiency.
Other Fields: It meets the experimental measurement needs of testing equipment and research institutes, and can be used as a core component for precise force measurement to support the development of scientific research and experimental work. It is also suitable for auxiliary force measurement scenarios in metallurgy, water treatment and other industries, providing protection for production safety and quality control.
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