Multi-Stage Intelligent Control Servo Tensioner with 2-2000gf Tension Range and Real-Time Display for Precision Coil Winding

Multi-Stage Intelligent Control Servo Tensioner

Tensioner is a necessary factor for keeping consistent winding accuracy.
Selecting better tensioner provides a sophisticated winding machine with best performance.
Stabilized tensioner improves winding problems and enhances productivity. For example,

stabilized tensioner causes no breaking of wire, raises operation rate, secures the value of

resistance, and increases credibility of the product.
Perfect layer winding leads to material cost cutting and easy adjustment. Therefore, time and cost

for machine maintenance can be decreased.
NHE Company has a wide range of tensioner types, from basic Magnetic type tensioners to

servo motor tensioners.

SFS Series: Multi-Stage Intelligent Control

(Best for: Complex, Safety-Critical, and High-Precision Coils)

This is the flagship "Smart Tensioner." It supports multi-stage programming, allowing you to set different tension values for different layers or sections of the coil. It also features a Visual Display Screen to monitor the tension curve in real-time.

Applications:

ABS Coils (Anti-lock Braking System): Requires absolute precision. You can reduce tension in outer layers to prevent the coil from bulging or cracking the bobbin.

Ignition Coils (Secondary Winding): For winding thousands of turns of ultra-fine wire (0.02mm), intelligent tension fluctuation compensation is critical.

Sensors & RFID Coils: Where electrical resistance consistency is strictly controlled.

Features of the SFS800 Dual Servo Tensioner:

1. Can be achieved tension range of 1-800gf and wire range of 0.02-0.4mm by replacing different specifications of tension rod and springs .

2. Principle & Structure:

Wire feeding adopts a closed-loop control mode with an angle sensor and a DC servo motor;Upper computer devices including the industrial control screen, PLC and motion controller regulate the extension length of both ends of the tension spring to achieve switching of multi-stage tension programs.(The extension of the upper end of the tension spring is driven by a set of servo motors; the extension control of the lower end of the tension spring is realized by adjusting the wire feeding angle of the angle sensor.)

3. Multi-stage Tension Switching

A. Preset 8 tension stages (corresponding to different working angles of the tension rod) directly on the tensioner display screen; the 8-stage tension parameter configuration can also be completed via RS485 communication, and the three-bit IO signal of the controller or PLC upper computer device enables program-controlled tension switching.

B. Upper computer devices including the industrial control screen, PLC and motion controller directly control the servo motor at the upper end of the tension spring to drive the spring’s extension length, thus achieving real-time control of tension magnitude switching.

4.Intelligent Networking Management

Via RS485 networking communication, the device enables data collection, online program upgrade and remote parameter adjustment, facilitating integrated management and control of production line equipment.

5. Alarm & Protection

Equipped with multiple early warning functions including wire break alarm, tension upper & lower limit alarm and equipment fault alarm, effectively avoiding the risks of production abnormalities.

• The standard configuration includes one tension rod and the corresponding tension - range spring.
• Select the suitable tension rod and corresponding spring according to the tension range.

Tension Rod Specification

Tension Spring Parameters

Appearance Structure and Wire - Hanging Schematic Diagram

Installation Instructions

Picture Display:

Frequently Asked Questions (FAQ)

Q1: What is the main advantage of Servo Tensioners over Magnetic Tensioners?

A: Magnetic tensioners rely on passive friction (braking), which causes tension fluctuation when winding speed changes.

NHE Servo Tensioners use an active wire feeding system with a built-in motor. It automatically adjusts the wire feed speed to

match the winding machine, ensuring constant tension even during rapid acceleration or deceleration.

This is critical for preventing breakage in fine wires (<0.1mm).

Q2: How do I choose between the SF (Single) and STD (Dual) series?

A: Choose SF Series: For standard coil winding, where tension remains constant.

Choose STD (Dual-Stage) Series: If your process requires wrapping the wire around the terminal pin at high speed.

You can set a higher tension for the pin wrapping (to ensure a tight connection) and a lower tension for

the main coil body (to prevent breakage), switching automatically via the machine's I/O signal.

Q3: Is it difficult to install these tensioners on my existing winding machine?

A: Not at all. The installation is straightforward. You only need to provide a DC 24V/48V power supply

and connect two signal wires (Ready/Alarm). We provide a detailed Wiring Diagram

and English Manual with every unit to guide your engineers.

Q4: Do I need to calibrate the tensioner?

A: Yes, for the highest precision, we recommend performing a "Zero Calibration" (Zeroing)

when installing a new tension arm or spring.The SF/SFQ series features a simple menu knob or

button to perform auto-zeroing in seconds.

Q5: What happens if the wire breaks during winding?

A: The tensioner has a built-in Wire Breakage Alarm. If the tension arm drops below the limit angle

(indicating a break or empty spool),the tensioner will immediately send a stop signal to your winding machine

to prevent producing defective parts.

Q6: How often should I replace the Tension Arm and Spring?

A: This depends on your usage intensity.

Tension Spring: We recommend checking its elasticity every 6 months.

Wool Felts & Ceramic Eyelets: These are wear parts. Check them monthly and replace them

if they show signs of grooves or wear to protect the wire insulation. NHE stocks all these spare parts for fast delivery.

Q7: Can I use one tensioner for different wire sizes?

A: Yes, but within a range. For example, the SF800 covers 10g-800g. If you switch from 0.05mm wire (low tension)

to 0.25mm wire (high tension), you may need to change the Tension Spring to a stiffer one to maintain stability.

We offer a full spring kit (T1-T19) for this purpose.

Q8: Why does the tensioner display an error code?

A: The LED display on SFQ/SFW models provides real-time diagnostics.

Common codes indicate "Over-current," "Over-speed," or "Limit Position Error."

Please refer to the User Manual provided by NHE, or contact our support team for a quick resolution.