Electrostatics & Electronic Tensioners

• Electrostatic Generation: During high-speed winding, friction between yarn and machine components causes a significant buildup of static electricity.
• Interference: This static charge can interfere with nearby sensors and actuators—especially sensitive electronic tensioners—causing incorrect readings and unstable yarn tension.
• Symptoms: Yarn tension spikes or drifts, erratic dancer movements, and faults in winding uniformity.

Solution: Servo-Type Tensioner Advantages

✅ Active Feedback Loop

• The servo motor continuously monitors yarn tension via high-resolution sensors.
• Any fluctuation caused by electrostatic interference is immediately corrected by real-time adjustments to the motor’s torque or brake force.

✅ Isolated Control Electronics

• Servo tensioners often have EMI/RFI shielding (Electromagnetic and Radio Frequency Interference), minimizing electrostatic impact on internal circuits.
• Some models have optically isolated I/O and are resistant to voltage spikes that static discharge might cause.

✅ Consistent Tension Across Variable Speeds

• Electrostatic buildup varies with yarn material, humidity, and speed. Servo tensioners maintain high tension accuracy, even as conditions change rapidly.

✅ Integration with Anti-Static Systems

• They can be integrated with ionizers or grounding brushes to neutralize static at the yarn path.
• The tensioner’s servo logic is designed to remain stable even if ambient static levels fluctuate.

Engineering Tips for Implementation

• Grounding: Ensure all machine frames, tensioner housings, and guides are properly grounded.
• Humidity Control: Maintain environmental humidity between 50–60% RH to reduce static formation.
• Yarn Path Design: Use ceramic or anti-static-coated guides where yarn friction is high.
• Servo Tuner Setup: Calibrate servo PID settings to tolerate minor noise but still react instantly to real tension changes.