WIRE TENSION MEASUREMENT
Wire tension measurement in wire production – Precise tension force measurement for stable processes, consistent quality, and less scrap
Consistent wire quality starts with controlled tension force.
In modern wire manufacturing and processing, precise wire tension measurement determines surface quality, dimensional accuracy, technical properties, and equipment availability. HAEHNE wire tension measurement systems enable continuous, low-contact tension measurement directly within the production process – reliable, robust, and highly precise.
- For manufacturers of wire, rope, stranded wire, and cable – from heavy-gauge to fine-gauge wire.
Why choose HAEHNE for wire tension measurement?
Errors caused by inaccurate or unstable tension
forces result in significant follow-up costs:
- Wire breaks and production interruptions
- Fluctuating diameters & surface defects
- Increased scrap and rework
- High wear on tension dies and guide rollers
- No reliable process data for quality and documentation
Without precise wire tension measurement, the
process remains a black box.
Our measurement systems guarantee you:
- Direct measurement of actual wire tension force
- Non-contact measurement without affecting the wire (low bending forces)
- High measurement accuracy even at high speeds
- Stable measurement values during temperature and load changes
- Integration into existing machines & control systems
HAEHNE Wire Tension Sensors – Designed for Wire Production
HAEHNE offers tension sensors specifically designed for wire, rope, and cable processes
Force measuring roller RMR3-series
The RMR3 series force measuring rollers are used to measure wire tension in basket and tube stranding machines. Thanks to their special design, the effects of centrifugal and Coriolis forces are fully compensated for.
Tension Force Measuring Roll ZAK
The ZAK series tension sensors were developed for the direct measurement of tension stress in cables, wires, ropes, or narrow strips.
Force measuring roller RCR-series
The RCR Series force measurement roller features a compact design and is used to measure tension force in sheet-like materials.
Tension Force Measuring Roll ZAD
The ZAD series tension measurement rollers are designed for direct measurement of tension force. Thanks to their external thread, they are particularly easy to install and are available with various rated forces starting at 10 N.
Versatile amplifiers,
easy commissioning
- Measurement amplifiers that are easy to use
- DMX amplifiers with a configuration app
- Quick setup
- Data logging available
- Drift-free
- 24/7 industrial-grade
With Strander Condition Monitoring, HAEHNE offers a comprehensive system for condition monitoring in stranding machines. This system centrally collects all data relevant to machine monitoring from the rotating components and transmits it via radio. The transmitted data is consolidated by the Fusion Center outside the rotating zone, where it can be analyzed and monitored via the dashboard.
DFT Transmitter Unit
(Digital Fusion Transmitter)
Mounted on the rotating part of the machine; Transmits tension, force, cradle lock, rotation, and temperature signals
DFC Receiver Unit
(Digital Fusion Center)
Mounted outside the rotating part of the machine; Receives all signals from the DFT
DFM Digital Monitoring and Analysis Unit
(Digital Fusion Monitoring)
Graphical display of received measurement signals for the operator
Which tension sensor sensor is right for your machine?
The biggest challenge in tension sensor measurement? Choosing the right sensor!
Every application is different:
- Different wire path geometries
- Varying installation conditions
- Materials & speeds
- Load ranges & safety factors
- Environmental conditions
That’s why our approach is: First, we understand your application – then we recommend the right solution
We specialize in wire tension measurement in the following areas:
Fine wire
Wire rope
Cable
Our digital advantage:
the HAEHNE-Configurator
You can check in advance which sensors are right for your application:
Sensor preselection, load ranges, roller integration – fast & intuitive
Uncontrolled wire tension costs money – every day!
Even the slightest deviations in wire tension can lead to: downtime, scrap, material cracks, deviations in technical properties, inaccurate winding results, and long setup times.
We develop measurement systems that:
- Directly measure the actual wire tension force
- Measure with minimal contact and without significantly affecting the wire
- Ensure high measurement accuracy even at high speeds
- Provide stable measurement values during tempera- ture and load changes
- Can be easily integrated into existing machines and control systems
This will allow you to:
- Greater process stability at increasing line speeds
- Measurement data for SPC, quality assurance, and documentation
- Reduced tool wear
- Foundation for control loops & automation
- Return on investment is often achieved in a very short time
- We consult before we sell. Sensor consultation with application expertise – both mechanical engineers and end customers benefit equally from decades of hands-on experience from our team. We optimise your process, together.
- Precise products for precise processes. High long-term stability and repeatability for applications where precision matters.
- German engineering, manufacturing & support. Directly accessible. Quickly available.
- Robust even in harsh industrial environments Our sensors operate reliably – even in the presence of: dust, heat, humidity, aggressive media, high machine loads, and vacuum conditions.
HAEHNE
Elektronische Messgeräte GmbH
Heinrich-Hertz-Straße 44
40699 Erkrath
Germany
+49 211 925 91-0
info@haehne.de
www.haehne.de
Your personal contact:
Guido Herper
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FAQ
Is it possible to retrofit existing wire tension machines?
Yes, the systems are ideally suited for retrofit projects.
Does the measurement affect the wire?
No, the measurement is performed with minimal contact via measuring rollers.
Are high speeds possible?
Yes, the systems are designed for high-speed industrial processes.
What materials can be measured?
Copper, aluminum, steel, precious metals, and special alloys.
Photo credits: | Title, Stock Photography ID:1292028944: ©iStockphoto.com/FabrikaCr https://www.istockphoto.com/de/portfolio/FabrikaCr?mediatype=photography | Fine wire, Stock Photography ID:1400748529: ©istockphoto.com/Nordroden https://www.istockphoto.com/de/portfolio/Nordroden?mediatype=photography | Cable orange, Stock Photography ID:516138738: ©iStockphoto.com/chengwaidefeng https://www.istockphoto.com/de/portfolio/chengwaidefeng?mediatype=photography | Cable environment, Stock Photography ID:170027240: © iStockphoto.com/fmajor https://www.istockphoto.com/de/portfolio/fmajor?mediatype=photography | Herper: HAEHNE Elektrotechnische Messgeräte GmbH