R2R Operational Insights: Tension Control Strategies for Winder and Unwinder

Running an unwinder or winder at the correct speed is critical for maintaining web quality and preventing defects. In practice, several well-established control strategies are commonly implemented in PLC systems, including:

• Position control using a rotational dancer
• Tension control with a load cell and speed adaptation
• Indirect tension control through torque adaptation
• Direct tension control through torque adaptation

MapleSim’s web handling simulation tool simplifies this process by providing ready-to-use components that reflect common PLC control strategies. These components make it easy to:

• Build and visualize control loops based on industry-standard approaches
• Model the entire machine in a way that’s easy to understand and tune
• Facilitate collaboration by using a single, clear diagram that mechanical, automation, and process engineers can all interpret consistently