ABB Millmate Strip Tension Gauge System (PXAH401)

ABB Millmate Strip Tension Gauge System (PXAH401)

Measurement principle: Presductor ®  Magnetoelastic effect (patented in 1954)

The steel material of the sensor body will change its magnetic properties under mechanical stress; Two sets of mutually perpendicular windings inside the sensor (primary excitation coil, secondary measurement coil). When there is no external force, there is no magnetic coupling between the two sets of coils, and the secondary has no output voltage.

After bearing the load, the magnetic permeability of the steel changes, the symmetry of the magnetic flux is destroyed, and a voltage signal proportional to the magnitude of the force is induced in the secondary. The sensor body has no mechanical moving parts and is a solid stainless steel structure with high rigidity, overload resistance, and vibration resistance.

Measurement Mode

Vertical measurement: Total force formula (F {Rtot}=T ( sin alpha+ sin beta)+ textTare ); Collect vertical force components and electronically compensate for the self weight (tare) of the rolling mill and bearings. Commonly used for tension detection between cold rolling mill stands.

Horizontal measurement: Total force formula (F {Rtot}=T ( cos beta --- cos alpha) ); Collecting horizontal force can eliminate the self weight of the roller and further improve measurement accuracy; Mostly used for continuous processing lines.

( alpha, beta ) is the wrap angle of the steel strip entering and exiting the turning roller.

Full range classification of load cells

All made of stainless steel material, suitable for protection against dust, water vapor, and corrosive environments in steel mills; Some models have an overload capacity of up to 30 times the rated load, high spring stiffness, and resistance to impact vibration.

1. PFBL141 series (vertical measurement, customized)

Application: Cold continuous rolling mill frame, multi roll rolling mill; There are two types of structures: fixed axis and rotating axis; Only sensitive to vertical forces, suppressing horizontal interference forces.

Range: Single sensor 4~400 kN; maximum overload 1100 kN.

Structure: Single roll and double roll installation structures; Large scale supports fully customized external dimensions.

2. PFCL201C/PFCL201CE (PillowBlock vertical measurement)

Application: pickling, annealing, galvanizing continuous processing line, also used for compact rolling mills; Installed under the bearing seat, detecting vertical force and measuring in both directions.

Range: 5-50 kN; Extended Range: 7.5-75 kN.

Version:

PFCL201C: Cannon aviation plug, suitable for handling cables;

PFCL201CE: Cable with protective hose integrated outlet, steel mill resistant to harsh working conditions version.

3. PFTL201C/CE/PFTL201D/DE (PillowBlock pillow type, large tonnage horizontal measurement)

Application: pickling, annealing, galvanizing line; Horizontal force measurement can eliminate the influence of roller weight and has high accuracy.

Range: C/CE: 10-50 kN; D/DE: 50-100 kN.

4. PFTL102A/AE/PFTL101B/BE (PillowBlock pillow type, small range horizontal measurement)

Application: Low tension process section, 0.5-20 kN; solid steel block processing, membrane structure, lateral load resistance, bidirectional horizontal measurement.

Version: A/B is for aviation plugs; AE/BE are fixed protective cable outlets; Linearity remains excellent within twice the rated load.

5. General performance indicators of sensors

parameter | indicator

Accuracy level ± 0.5% FS (rated range); Expand range ± 1% FS

Linear deviation ± 0.3~± 0.5% FS

Delay 0.2% FS

Repeatability<± 0.05% FS

Zero temperature drift 0.003-0.005%/K

Working temperature -10~+90 ℃ (PFTL101 can reach -10~+105 ℃)

Storage temperature -40~+90/105 ℃

Definition: Rated load Fnom: calibrated total load (static load+maximum measured tension); Extended range Fext: The maximum measurement load that can still ensure accuracy; Overload: The maximum force that does not change the calibration parameters.

Millmate Controller 400 (MC400/400R)

The controller provides excitation power to the sensor, processes the sensor signal, completes tension calculation, and outputs to the external interface.

Core Functions

Built in algorithms for various mechanical installation configurations, automatically converting the input package angles α and β to the actual tension of the steel strip; Built in sensor parameter table.

Pre define multiple standard measurement modes; Support multi controller interconnection; Support unit switching: N, kN, MN, t, lb, etc.

Signal filtering time: configurable from 5 to 500ms; Built in self diagnosis, including sensor fault detection.

I/O interface (electrical group isolation)

Sensor excitation output; Up to 4 sensor analog inputs;

4 analog outputs (0-10V/0-20mA/4-20mA isolated); Step response 5ms (0-90%);

8 digital inputs and 8 digital outputs; +24V external supply (maximum 0.5A);

Serial port: 2 × RS-232, 1 × RS-485; Ethernet TCP/IP; Optional PROFIBUS fieldbus (refresh cycle 1.5ms).

Hardware Specifications

Appearance: 380mm x 235mm x 90mm; Weight: 5kg; Protection level: IP20;

Power supply: 85-264V wide AC input; Power consumption 140   VA;

Working temperature: 0~+70 ℃; Storage -40~+70 ℃.

Attention: The same controller cannot mix sensors with different excitation specifications.

Supporting optional components

Installation of human-machine interface for Millmate Operator Unit 400 operation unit panel; IP65 panel front, IP20 in other directions; Size 160 × 235 × 60   mm, weight 1.3   kg; TCP/IP Ethernet and controller networking, 24VDC power supply; Used for parameter setting, tension value display, and fault viewing.

PFBC161 junction box extends the distance between the controller and the sensor, reducing wiring costs; IP65； 150 × 150 × 80   mm, weighing 1.7   kg.

PXUB201 isolation amplifier: improves electrical isolation performance; Input 0-5V/± 10V; basic insulation withstand voltage 600V, 24V power supply.

PFVK128 relay board: 4-channel conversion relay; 24VDC； Contact AC250V/8A.

cabinet

Ground mounted MNS cabinet: IP21 ventilated type/IP54 enclosed type; 2225×740×656 mm，150‑200kg；

Wall mounted cabinet: IP65; 500 × 400 × 200   mm, weighing 22   kg, the operating unit can be installed on the cabinet door.

System architecture and application scenarios

Network hierarchy: sensors - junction boxes - controllers; The controller is connected to the fieldbus, and then connected to the local area network and upper layer factory network in the factory area, supporting remote access.

Typical applications:

Tension between rolling mill stands (PFBL141 vertical sensor);

Pickling, continuous annealing, galvanizing line (PFCL201 pillow type vertical; PFTL201, PFTL101 horizontal pillow type.

ABB provides complete solution support: mechanical accessories, installation plans, selection guidance, and can customize sensors for non-standard rolling mill geometries.