The core working principle of winding machine tensioner is to generate adjustable damping force through mechanical, magnetic damping or electronic control, so that the wire maintains stable tension during winding process and ensures uniform tightness of coil. The specific types and principles are as follows:
Magnetic damping tensioner
Core mechanism: Use magnetic field to transmit constant torque without mechanical contact friction. The magnetic field strength is changed by adjusting the distance between the magnetic disk and the damping disk, thereby controlling the tension.
Advantages: No sliding friction, long service life, stable tension.
Wide tension range (5g~8000g), suitable for high-speed winding.
Application scenario: Transformer and motor coil production that requires long-term stable tension, such as permanent magnet tension controller.
Mechanical (friction) tensioner
Core mechanism: Rely on the friction between metal disk and felt/canvas to generate damping. The clamping force is adjusted by the spring lever mechanism to change the friction torque.
Adjustment method: Manual knob controls pressure, similar to the physical principle of "pinching the rope".
Limitations: After long-term use, the tension fluctuates due to wear and tear, which is suitable for low-cost, low-precision scenarios, such as hand-wound crafts.
Electronic tensioner Core mechanism: The hysteresis device is controlled by the excitation current to generate hysteresis torque to achieve closed-loop tension control.
Features: The tension is independent of the winding speed, and the accuracy can reach ±2%, which supports high-speed winding. Programmable control of two-stage tension switching, such as electronic hysteresis.
Applicable scenarios: Transformer and precision coil production with high-precision requirements.
Servo tensioner (active wire feeding type) Core mechanism: The motor actively follows the winding machine to directly control the wire feeding speed and tension to achieve dynamic adjustment.
Advantages: Suitable for complex winding paths and high-precision demand scenarios.
