Web Tension & Winding Tools

Translate a tested material tension into force, torque, taper, pneumatic dancer pressure and acceleration demand without confusing roll inventory geometry with machine setpoints.

Choose the operating decision

Web Tension Force Calculator

Convert N/mm, N/m or PLI into the total force carried across the running web.

Winding Torque Calculator

Calculate force-times-radius torque at the current roll diameter.

Taper Tension Planner

Expose a linear diameter-based reduction from core tension to full-roll tension.

Dancer Pressure Calculator

Relate web spans and lever geometry to pneumatic cylinder pressure.

Winder Acceleration Torque

Add roll inertia and speed-ramp demand to steady tension torque.

Five independent decisions

Unit tension selects no actuator until web width creates total force. Total force creates different torque at every radius. Taper defines how the force target changes through the build. A dancer converts that force through its own geometry, while acceleration adds a separate inertial demand to the drive.

Recommended sequence

Obtain a tested tension-per-width window for the exact material and process.
Convert it to total web force at the active width.
Calculate torque at core, running and full-roll diameters.
Model the approved taper definition and compare it with the controller manual.
Cross-check dancer pressure or drive ramp demand against actual machine geometry.
Run at low speed, verify load-cell readings and record the approved setup.

Scope and limits

These tools calculate transparent nominal mechanics from user-supplied specifications. They do not recommend safe material tension, replace machine guarding or perform final motor, brake, clutch, core or structural sizing.

Use the Web Tension & Winding Setup Guide for the full commissioning checklist. Last reviewed: 2026-08-27.