TT-25: the new generation of Re tension controllers

Every great story deserves a worthy successor.
After more than twenty years of success, T-One passes the baton to the new TT-25, the tension controller that builds on Re’s experience and takes it into the future.

Some products, over time, become part of a company’s history. For Re, one of them is undoubtedly T-One: for more than twenty years, it has been one of our reference products in web tension control, chosen by machine builders and converters worldwide for its reliability, robustness and ease of use.

Replacing it was therefore not an easy decision.

“T-One was still doing its job flawlessly and customers continued to appreciate it. But the market was changing, technology was evolving, and we had to evolve with it.”

Modern converting lines require increasingly advanced automation, greater precision, faster response times, intuitive interfaces and seamless integration with machine architectures.

TT-25 addresses these requirements with an advanced PID algorithm developed to provide faster response and greater tension-control accuracy, even in the most dynamic applications.

The human-machine interface has been completely redesigned around a 4-inch colour touchscreen, a new graphical interface and multilingual navigation, making parameter configuration, diagnostics and monitoring straightforward and immediate.

Connectivity also takes a major step forward: PROFINET and EtherCAT communication allow TT-25 to integrate into modern automation networks and communicate directly with PLCs and supervisory systems.

One of the key decisions behind the project was not to develop TT-25 around a single application. Instead, we created a platform capable of adapting to the different architectures used for web tension control. This approach resulted in four configurations.

• TT-25 L controls web tension during unwinding and rewinding using load cells or a dancer roller together with the roll diameter signal.
• TT-25 XL is designed for advanced modular brake management, activating and deactivating brake calipers to dynamically adapt torque to the required web tension. It also provides tension control for splicing systems.
• TT-25 FPM controls electromagnetic powder brakes via a PWM output, without requiring external power boards.
• TT-25 MTR is designed for motor-driven unwinders, rewinders and traction systems, using the line speed reference together with signals from load cells and the diameter sensor to control torque and/or speed.

“We did not want customers to adapt their machines to the controller. We wanted the controller to adapt to the application.”

TT-25 draws on more than fifty years of Re experience in tension control and thousands of applications developed together with our customers. Its ambition is significant: to become for the next generation of machine builders and converters what T-One was for the previous one.

Some products simply do their job. Others leave a legacy.

TT-25 was created to carry that legacy forward, with the same spirit that made T-One a success and with its sights set on the next twenty years of innovation.

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