Tension Data Logger

Winding Equipment We Trust — Tested in Our Own Production

Real-time wire tension monitoring for coil and transformer winding: 0–3000 g, ±5 g accuracy, 64 channels, alarm with machine stop, USB/MES data export.

Winding MaterialCopper / Enameled / Litz / Aluminum / Flat / Self-bonding / etc.

Winding Precision± 0.01mm

Winding TurnsCustomizable (1T – 10,000T)

Minimum Order QtyCustomizable

Lead Time7–15 business days

Payment TermsT/T, L/C, Western Union

Send Email

Typically responds within 24 hours · Free samples available

30+ Years Experience

ISO Certified Factory

Shipped to 30+ Countries

This system is used for real-time monitoring of wire tension during the winding process for transformers, coils, and other components. Each workstation is equipped with a strain-gauge tension sensor capable of measuring instantaneous wire tension within 0.1 seconds, and the system can simultaneously monitor up to 64 sets of tensioners. The system collects and records tension data for each winding operation in real time. It automatically triggers an alarm when tension exceeds the set range and can trigger the winding machine to stop. Data can be exported via USB or Ethernet and can also be integrated with a computer or MES system.

Real-Time Data Collection

• Instantaneous Tension Measurement: Measures instantaneous wire tension within 0.1 seconds, with each 0.1-second interval further subdivided into 10 data samples.

• Simultaneous Multi-Channel Monitoring: Simultaneously collects and displays data from up to 64 tension sensors, supporting multi-axis and multi-wire-group displays.

• Full-Process Recording: Real-time data for every winding operation of each transformer is collected and stored.

Data Management

• Data Export: Real-time data can be exported via an external USB or network port, supporting connection to a computer or MES system.

• Archiving by Sensor: Each sensor can be assigned a unique ID, and data is pushed separately and accurately based on that ID.

Alarms and Interlocked Shutdown

• Range Alarms: Upper and lower limits for winding tension can be set; an alarm is triggered when the tension exceeds these limits.

• Alarm Trigger Conditions: An alarm is triggered when one or more channels exceed the set limits three consecutive times; values exceeding the limits are displayed in red.

• Interlocked Shutdown: The controller can be connected to an audible and visual alarm on the winding machine; when an alarm is triggered, the winding machine will automatically shut down.

Calibration and Settings

• On-Demand Calibration: Individual sensors can be calibrated to standard values at any time, and their channel numbers can be set as needed.

• Flexible Channel Configuration: The number of channels displayed can be set according to actual winding requirements, in the format “number of spindles × number of wires per spindle.” For example, select 12×1 for 12-spindle single-wire winding, and 16×3 for 16-spindle 3-wire winding.

Applications

Smartphones & 3C Electronics

Automotive Electronics

Industrial Sensors

Precision Instruments

Audio Equipment

Wireless Charging

Category	Item	Parameters
Structure	Size	130 × 42 × 29 mm
	Housing Material	White ABS plastic (glass-reinforced)
	Protection Rating	IP65
Measurement	Sensor Type	Strain-Gauge Load Cell
	Measurement Range	≤ 3000 g
	Measurement Accuracy	± 5 g
	Sampling Rate	200 per/second Max
	Safe Overload	150% FS
	Extreme Overload	200% FS
Electrical	Communication Interfaces	RS485(main controller with a separate Ethernet port.)
	Signal Input	Low-frequency electrical signals
	Impedance	500 Ω
	VSWR	≤ 1.3
Environment	Operating Temperature	−35 ℃ ~ +70 ℃

Our standard MOQ is 500 pcs for most coil types. For first-time customers or prototype evaluation, we accept small trial orders of 10-50 pcs. MOQ may vary by product complexity. Contact us for a specific quote.

Yes. Samples are available within 5-7 business days after engineering confirmation. A nominal sample fee applies, which is credited toward your first mass production order.

You can email drawings such as PDF, DWG, or STEP files, or fill out our inquiry form. If you do not have drawings, a written description or physical sample is also acceptable.

We can wind wire as fine as 0.01mm using Zongheng CNC precision winding machines with automated tension control.

Yes. Our special-shaped coil series handles non-circular and irregular geometries. Submit your drawings and our engineering team will assess feasibility.

Standard options include bare copper wire, enameled copper wire, and Litz wire. Custom alloy or coated wire options are available on request.

Yes. Provide your target inductance, frequency, and DC resistance requirements, and we will calculate and wind to specification.

WIRESUN is ISO 9001 certified. Products can ship with test reports and COA. Third-party inspection can be arranged upon request.

All coils are wound on CNC machines with precision control. Each production batch undergoes electrical testing, including inductance, DCR, and impedance checks.

Standard documentation includes packing list, commercial invoice, Certificate of Analysis, and electrical test report. RoHS/REACH documents are available upon request.

We ship worldwide. Regular destinations include Southeast Asia, Europe, the Americas, the Middle East, and Russia. Express and sea freight options are available.

Standard terms are 30% T/T deposit upon order confirmation and 70% balance before shipment. L/C is accepted for larger orders, and Western Union is available for sample fees.

Standard products usually take 15-20 business days. Complex custom coils generally take 20-30 business days. Final lead time is confirmed at quotation stage.