Filament Tri-Wheel™ Tension Load Cell

A modular, configurable load cell fixture designed to measure the tension of wire, cable or filament processes.

The Tri-Wheel™ Tension Load Cell is a modular fixture designed to be installed individually or stacked in an array. The system incorporates a set of wheels with adjustable positions, allowing an operator to select from multiple wrap angles. The minimum wrap angle position can be helpful when working with high tension applications or rigid materials with bend limitations. The maximum wrap angle narrows the measurement range of the load cell to deliver the highest possible accuracy and resolution for the selected load rating.

The heart of the Tri-Wheel™ system is a high-performance semiconductor strain gauge load cell providing up to 33 times more signal output than similar foil gauge systems. The Tri-Wheel™ fixture incorporates ceramic pulleys able to withstand wear from steel, copper, glass, carbon fiber and composite filament. Designed with quick integration in mind, the Tri-Wheel™ system is compatible with DFE amplifiers, indicators and controllers featuring Quik-Cal™ technology for rapid, reliable calibration.

Tension is measured by strain gauges embedded on a dual cantilevered beam and connected in a full Wheatstone bridge configuration. As the filament passes over the rotating wheel assembly coupled to the end of the transducer, the beam deflects slightly in response to tension. This produces a voltage signal proportional to tension. The output signal can be displayed as actual tension with a tension indicator or input to a closed-loop tension controller to modulate a torque device and maintain a precise tension set point.

5 year tension-free warranty
• Highly accurate and reliable semiconductor strain gage technology
• Stackable form-factor
• 50mm pulley fits filaments up to 6mm in diameter
• Ceramic wear surfaces for reliability and long-life
• Load ratings available from 10 – 200 lbs (45 – 890N) for a wide operating range
• Configurable wrap angles for a wide selection of tension ranges and material paths

• Accurate tension measurement of any wire, cable or filament
• Improve product quality and consistency in any filament process
• Reduced material waste
• Higher production with less downtime

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Excitation: 5 VDC Max
Output: 100 mV/V, Nominal
Strain Gages: Semiconductor, 100 Ohms, nominal
Circuit Configuration: Full Wheatstone Bridge
Non-Repeatability: ±1/4% Full Span (FS)
Combined Non-Linearity & Hysteresis:
  ±1/2% Full Span (FS)
Temperature Range: -10°F to 200°F (-23°C to 93°C)
Temperature Coefficient:
  .02% FS per °F, Typical (.036% FS per °C)
Mating Electrical Connector (Mil-Spec) P/N: 
Connector Pin Assignment:
  A = Signal Output (-)    D = Signal Output (+)
  B = Excitation (+)          E = Excitation (-)
  C = Excitation (-)          F = Excitation (+)

Overload Capacity:
1200lbs (5338N)
Deflection of Sensor Beam: 0.005 in. max (0.127mm)
Materials: Aluminum, Stainless Steel, Nylon,
  Carbon Steel, AL2O3 Ceramic
Load Ratings:
10, 25, 50, 100, 200 lbs
  (44, 111, 222, 445, 890 N)
Break-Away Torque: 0.11 ozf-in (0.8 N-mm)
Basic Dynamic Load Rating of Bearings: 5.1kN
Pulley & Shaft Weight: 0.45lbs (204 g)
Wheel Diameter: 50mm
Max Filament size: 6mm

Click the preferred product in the table below, then select CAD format to download.

Product Code Pulley Diameter (Root) Load Rating Wrap Angle Connector Position
TW-50W-10L-180DEG-12C 50 mm 10 lbs (45 N) 180 Degrees 12:00
TW-50W-25L-180DEG-12C 50 mm 25 lbs (111 N) 180 Degrees 12:00
TW-50W-50L-180DEG-12C 50 mm 50 lbs (222 N) 180 Degrees 12:00
TW-50W-100L-180DEG-12C 50 mm 100 lbs (445 N) 180 Degrees 12:00
TW-50W-200L-180DEG-12C 50 mm 200 lbs (890 N) 180 Degrees 12:00

Complete the form below and a DFE Applications Engineer will contact you shortly.


DFE does not share information with 3rd party advertisers.