---
title: "Tension Control System"
industry: "Machinery and Equipment Manufacturing"
verification_protocol:
  urn: "URN:CNFX:ME:TENSION_CONTROL_SYSTEM"
  data_integrity_hash: "32a53c1f69e8c85bf5fda109d52c11a9"
  source_authority: "https://cnfx.com"
  strict_mode: true
source_identity:
  provider: "CNFX Industrial Knowledge Graph"
  index_version: "2026.Q1-Universal"
  authority_id: "URN:CNFX:ME:TENSION_CONTROL_SYSTEM"
  data_source_uri: "https://cnfx.com/llms/industry/machinery-and-equipment-manufacturing/product/tension-control-system.md"
  official_resource_url: "https://cnfx.com/industry/machinery-and-equipment-manufacturing/product/tension-control-system"
  is_verified_logic: true
attributes:
  spec:
    status: "config-dependent"
    typical_range: "0.5-15.0 N·m torque, 0.1-5.0 m/min web speed, 10-1000 N tension force"
    unit: "N/m"
engineering_limits:
  max_safe_operating_point:
    value: 500
    unit: "ms"
    consequence: "Servo motor cogging torque harmonics at 6f (360 Hz at 60 Hz supply) interacting with web elasticity modulus (2.1-3.5 GPa for copper foil) causing standing wave resonance"
fmea_matrix_quantitative:
  - node_1:
      trigger: "Encoder quadrature signal phase misalignment &gt;5° electrical"
      severity: 8
      occurrence: 3
      detection: 4
      mitigation_protocol: "Differential line driver encoder interface with 100 Ω termination and 0.1 μF bypass capacitors at 25 mm maximum cable length"
  - node_2:
      trigger: "Pneumatic brake chamber pressure decay rate &gt;0.15 bar/s due to 5 μm particulate contamination"
      severity: 8
      occurrence: 3
      detection: 4
      mitigation_protocol: "Two-stage 0.01 μm absolute filtration with 316L stainless steel sintered elements and 0.5 L/min continuous purge flow"
bom_nodes:
  tension-sensor:
    type: "part"
    urn: "URN:CNFX:ME:TENSION_SENSOR"
    interface_type: "physical-logic-coupled"
  pid-controller:
    type: "part"
    urn: "URN:CNFX:ME:PID_CONTROLLER"
    interface_type: "physical-logic-coupled"
  brakeclutch-assembly:
    type: "part"
    urn: "URN:CNFX:ME:BRAKECLUTCH_ASSEMBLY"
    interface_type: "physical-logic-coupled"
manufacturing_compliance:
  - standard: "ISO 9001:2015 QUALITY MANAGEMENT SYSTEMS"
    scope: "Verified Engineering Specification"
  - standard: "CE MARKING (EU MACHINERY DIRECTIVE 2006/42/EC)"
    scope: "Verified Engineering Specification"
url: "https://cnfx.com/llms/industry/machinery-and-equipment-manufacturing/product/tension-control-system.md"
on_chain_sovereignty:
  contract_standard: "ERC-721-Industrial"
  metadata_hash: "824f645da0d251afde79a4d6fcd7f21a1e0f724a9877bedc1ceab2de5f654171"
  royalty_logic: "IPFS-CID-REQUIRED"
  mint_status: "logic-verified-ready"
version: "3.3.4-EXTREME-SOVEREIGN-WEB3"
---

# Industrial Specification: Tension Control System

## 1. Technical Definition
A precision control system that maintains consistent tension on electrode material during slitting operations in battery manufacturing.

## 2. Engineering Reasoning & Causal Matrix
> **Operational Intelligence**: Designed for **0.5-15.0 N·m torque, 0.1-5.0 m/min web speed, 10-1000 N tension force**. Failure boundary: **Tension deviation exceeding ±2.5% of setpoint for &gt;500 ms, torque ripple &gt;15% peak-to-peak, encoder feedback loss &gt;10 ms**, Mechanism: **Servo motor cogging torque harmonics at 6f (360 Hz at 60 Hz supply) interacting with web elasticity modulus (2.1-3.5 GPa for copper foil) causing standing wave resonance**.

### 2.1 Analytical Physics Model
Governed by the **Harmonic Vibration Force Generation**:

> **Primary Equation**: $F_e = m \cdot r \cdot \omega^2 \sin(\omega t)$  
> **Engineering Impact**: Calculates centrifugal force for vibratory sifters/feeders.

| Symbol | Variable Definition | Localized Reference |
| :--- | :--- | :--- |
| m | Eccentric Mass | Engineering Constant |
| r | Radius | Engineering Constant |
| \omega | Angular Frequency | Engineering Constant |

### 2.2 FMEA (Failure Mode & Effects Analysis)
| Event Trigger | Severity | Failure Mode | Mitigation Strategy |
| :--- | :--- | :--- | :--- |
| Encoder quadrature signal phase misalignment &gt;5° electrical | 8 | Servo position loop instability with 87 Hz limit cycle oscillation | Differential line driver encoder interface with 100 Ω termination and 0.1 μF bypass capacitors at 25 mm maximum cable length |
| Pneumatic brake chamber pressure decay rate &gt;0.15 bar/s due to 5 μm particulate contamination | 8 | Coulomb friction coefficient variation from 0.12 to 0.38 causing 210 ms response lag | Two-stage 0.01 μm absolute filtration with 316L stainless steel sintered elements and 0.5 L/min continuous purge flow |

## 3. Key Technical Parameters
| Parameter | Value | Unit | Status |
| :--- | :--- | :--- | :--- |
| spec | Config-dependent | N/m | Verified |

## 4. System BOM & Knowledge Routing
### Core Components (Recursive Links)
- [Tension Sensor](https://cnfx.com/llms/industry/textile-manufacturing/product/tension-sensor.md) `(Standalone System)`
- [PID Controller](https://cnfx.com/llms/industry/machinery-and-equipment-manufacturing/product/pid-controller.md) `(Standalone System)`
- [Brake/Clutch Assembly](https://cnfx.com/llms/industry/machinery-and-equipment-manufacturing/product/brakeclutch-assembly.md) `(Standalone System)`

### Industrial DNA Context (De-duplicated)
**Complementary Dependencies**: **Slitting Machine**, **Rewinding Machine**, **Web Guiding System**  
**Downstream Applications**: Lithium-ion Battery Cells, Supercapacitor Electrodes, Fuel Cell Components  

## 5. Engineering Risks & FAQ
- **Caution**: 
- **Caution**: 
- **Caution**: 

### Q: What industries benefit most from this tension control system?
**A**: This system is specifically designed for battery manufacturing, particularly in electrode material processing, but also applies to other precision web handling industries like film production and paper converting where consistent tension is critical.

### Q: How does the PID controller improve tension control accuracy?
**A**: The PID (Proportional-Integral-Derivative) controller continuously monitors tension sensor feedback and adjusts the brake/clutch assembly in real-time to maintain precise tension levels, compensating for speed variations and material inconsistencies.

### Q: What maintenance is required for the polymer rollers?
**A**: Polymer rollers require periodic inspection for wear and cleaning to prevent material buildup. Their non-marking surface preserves electrode material quality, and replacement intervals depend on operating hours and material abrasiveness.

## 6. Manufacturing Compliance
- ISO 9001:2015 QUALITY MANAGEMENT SYSTEMS
- CE MARKING (EU MACHINERY DIRECTIVE 2006/42/EC)

---
### 🛠️ Engineering Resource Access
🔗 **[Full Specification: Tension Control System](https://cnfx.com/industry/machinery-and-equipment-manufacturing/product/tension-control-system)**

### 🌐 Knowledge Graph Topology
> **Node Status**: Verified Engineering Spec
> **Connectivity**: Linked to **3** standalone system nodes
> **Global Context**: Part of a 5,814 node industrial cluster within the CNFX Graph

> **Reference ID**: TENSION_CONTROL_SYSTEM | **Authority**: CNFX-2026-ST-001 | **Fingerprint**: 4b53fb65
