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TR Tension Roll® Transducers

DFE recently shipped the company's 10,000th Tension Roll transducer to a major North American narrow web printing press manufacturer.

The Tension Roll Transducer pictured above was shipped to a major plastics manufacturer for a wide-web film converting application. The roll is 94 inches long, with a 5-inch diameter. The shaft is 113 inches long. DFE makes all TR's to order with fast turn-around times to meet our customers' critical demands.

RoHS compliantCE mark*

Pair your Tension Roll transducer with a SteadyWeb5 Tension Controller for the most accurate web tension control system in the industry.

Digital Tension Controller

Save Money Refurbish your existing Tension Roll Transducers

At about half the cost of a brand new Tension Roll Transducer, we'll refurbish and refinish your existing unit to look and perform like new. Click the link above to find out how.

TR tension rollers before and after being refurbished.

Users are delighted with the precision performance and robust reliability of the TR Tension Roll® transducer, a unique sensing device for accurately measuring process web tension in any substrate.

A dead-shaft idler roller with tension sensors built into each roll end, the Tension Roll® transducer is ideal for installation on original equipment or for retrofits since it arrives pre-assembled and ready-to-install between the facing sides of a machine frame. It can be inserted into an appropriate web path location, and an accurate web tension value can be displayed on a connected indicator or controller.

No assembly required.

With the TR transducer the engineering time required to size the unit to the machine frame prior to installation is significantly lower than when installing standard shaft-end load cells or tension transducers onto an idler roll.

Another advantage of the Tension Roll transducer over a conventional idler roll with transducers is that it requires only a single transducer cable to connect at one end of the roll. The transducer's connector cable never has to cross the machine.

   Tension Roll Transducer


For web presses and machines that run an extreme range of materials and tensions, the Tension Roll transducer can be mounted in a pair of DFE's model C shaft-end tension transducers . This allows one range of tensions to be measured by the Tension Roll's sensors, while a higher load range can be measured using the externally-mounted tension transducers. This feature is convenient in the rare cases that a machine's tension range exceeds the 100:1 maximum-to-minimum tension ratio of DFE's extended range option.

The Tension Roll transducer is available with three (3) standard roll materials including aluminum, steel or stainless steel. Special roll surface materials are available. The standard overload capacity on the largest unit is 3,000 lbs (13,300 N).

Roll face width is sized individually (from 6 inches [152mm] up to 120 inches [3.0 m] ) to fit almost any application requirement. Choose a roll diameter from 2.25 inches (57mm) up to 6 inches (152mm) standard, or another custom diameter to fit your application. Load ratings from 12 to 400 pounds (55 to 1800N).

Tension Transducers Capabilities

  • Transducers and idler roll in one, easy-to-install unit
  • Fast, hassle-free installation--like any dead-shaft idler roll
  • Aluminum, steel or stainless steel rolls in many surface finishes
  • Now in Three frame sizes plus many custom variations
  • One electrical cable

Just specify your desired shaft length, load rating, roll diameter and any options or a special roll finish.

Roll and Shaft Configuration

This is faster, easier and less expensive than installing a separate idler roller with 2 transducers (a.k.a load cells). Only one transducer cable is used, meaning there is no cable-crossing between machine frames. Aluminum, steel or stainless steel rolls are available in many surface finishes.

Note of interest: The TR Tension Roll® Transducer is also referred to by some of our customers as the Dover Roller, the Tension Roller and sometimes the Tension Measurement Roller. Any way you like it, this is the easiest way for printers and manufacturers to measure web tension on a press, converting line or coating line.

Do you need a Tension Roll transducer with multiple transducer segments across the roll face? DFE makes a custom Tension Roll, called a Segmented Tension Roll transducer that measures web tension at multiple positions across the roll face at increments you specify. Find out more here.

Segmented Rension Roll

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*CE-marked DFE Transducers are certified to conform with CE Requirements when used as accessories intended for use with CE-marked DFE electronics products (amplifiers, indicators).