Consistent and accurate tension control is essential in wire and cable manufacturing. Every stage of production, from wire drawing to insulation, taping, armouring and final winding,  depends on stable forces acting on the material. Even slight deviations can cause conductor damage, insulation defects, shape distortion or variation in cable diameter, ultimately affecting product performance and reliability.

Modern force measurement systems play a vital role in stabilising these processes. By continuously monitoring and regulating tension, they help manufacturers maintain quality, reduce scrap, avoid downtime and ensure that production lines run reliably under high demand.

This article explores how force measurement systems work, why they are indispensable in the wire and cable industry and how they contribute to more efficient and predictable production.

Why tension control matters in cable manufacturing

Cable production is highly sensitive to tension fluctuations because cable materials, especially copper, aluminium and multi-layer insulation, respond mechanically to force.

1. Conductor deformation

If the tension is too high, the conductor may stretch and change its cross-sectional area, impacting electrical conductivity and mechanical strength.

2. Insulation and sheath defects

During extrusion, excessive tension can cause:

  • Non-concentric insulation
  • Uneven wall thickness
  • Surface damage
  • Reduced dielectric strength

Topics such as insulation quality also relate to encoder-based feedback systems used in motion control systems, which further stabilise the production line.

3. Diameter and roundness variation

Tension impacts cooling, pulling speed and deformation. Stable tension ensures stable geometry.

4. Winding faults

Irregular tension during final spooling causes defects such as telescoping, crushed coils or loose layers.

5. Line instability and downtime

High-speed lines are especially vulnerable; a single break can stop production for hours, affecting output planning.

These issues are even more critical in high-end industries such as speciality cables, fibre optics and heavy-duty applications like those featured in Euro-Hubner’s heavy duty industry solutions.

How force measurement systems improve process stability

1. High-accuracy, real-time monitoring

Force measurement systems provide continuous live feedback on the tension applied to the material. Sensors detect even the smallest changes and immediately communicate them to the PLC or drive controller.

Euro-Hübner’s systems are engineered for:

  • High measurement precision
  • Fast dynamic response
  • Long-term stability
  • Resistance to vibration, temperature changes and contamination

Stable measurement is the foundation for consistent production quality.

2. Automated closed-loop control

Force sensors don’t just monitor tension; they actively help regulate it. A closed-loop setup integrates measurement feedback with:

  • Motor drives
  • Dancer arms
  • Braking systems
  • Torque control mechanisms

For example, electromagnetic brake systems (as explained in detail in What are electromagnetic brakes and the electromagnetic brakes product page) are often used to stabilise pay-off reels.

When tension rises unexpectedly, the system reduces braking force or motor torque. When tension drops, the system compensates automatically. The result: stable, predictable and smooth material flow across the whole production line.

3. Scrap reduction and fewer line interruptions

A well-calibrated force measurement system prevents:

  • Wire breaks
  • Deformation during insulation
  • Over-tension during taping
  • Layer misalignment
  • Excessive stretching in fibre optic lines

Because issues are detected early, parameters can be corrected before the product becomes unusable, drastically lowering scrap rates.

4. Integration with web guiding and alignment systems

In many processes, especially wrapping, taping, coating or applying protective layers, both alignment and tension must be controlled. Force measurement systems work seamlessly with web guide systems to ensure:

  • Perfect lateral alignment
  • Constant force on tapes or films
  • Reduced wrinkling
  • Better surface finish
  • Less material waste

For multi-layer or foil-wrapped cables, combining web guiding with precise force measurement is essential.

Force measurement systems throughout the production chain

Extrusion and insulation

Maintains conductor stability to ensure concentric and even insulation application.

Stranding

Balances forces between multiple wires or cores to prevent twisting or structural distortion.

Armouring and taping

Applies steel, PVC, aluminium or fibre layers with stable tension to avoid gaps or overlaps.

Printing and marking

Maintains consistent material flow for accurate, continuous marking.

Winding and packaging

Ensures perfect coil geometry, reduced reel defects and easier further processing.

How force measurement interacts with encoder technology

Many advanced cable lines combine force measurement with encoder feedback from:

Encoders measure speed, position and acceleration, which is essential for synchronising line segments.  Force measurement ensures that the physical load on the cable remains stable.

Together, they form an integrated motion control solution.

Choosing the right force measurement system

Important considerations include:

  • Tension range
  • Material type (metal wire, fibre optics, tapes, films, coated cable)
  • Maximum line speed
  • Sensor mounting options
  • Environmental exposure (heat, humidity, vibration)
  • Communication protocol
  • Compatibility with drive, encoder and PLC systems

Euro-Hübner’s engineering team provides support with system design, sensor selection, commissioning and calibration to ensure an optimal solution for each application.

Conclusion

Force measurement systems are indispensable for achieving stable, efficient and high-quality cable production. When integrated with encoder technology, electromagnetic brakes and web guiding systems, they contribute to robust motion control systems and significantly reduce operational risk.

With decades of experience in the cable industry and a full range of measurement and control solutions, Euro-Hübner Benelux B.V. helps manufacturers create reliable, predictable and energy-efficient production environments.