Talk to me about whisker disks

[David King]

There are all manner of fine wire tension meters available that clamp onto your wire and tell you either on an analogue meter or digitally what your tension is. They can measure from 1 gram and up. I can't figure out what they cost but they are pretty simple looking devices you could make yourself. They work by pushing on the wire running between 3 small pulleys that are spring loaded. You could use this to set and check your tension through the felts. One problem is undoubtedly that your tension is constantly changing as the wire get pulled faster or slower over the ends of the bobbin.
Tensitron - Products - Fine Wire & Filament Tension Meters
ZEF / ZED Economical Digital Tension Meter

[ReWind]

Hey David, thanks! I called Albuquerque Industrial about those, actually. Didn't get a call back yet. A device like that could be very hand for measuring the tension at different points along the line. ...as long as they are inexpensive.

I DID however speak to my contact at Azonic this morning and he's sending me some new lighter tension equipment (again on a free trial) to, hopefully, resolve my issues. I do hope to get their products working consistently, when they work, I'm happy with the results. Either way though, I can say that they are an absolute pleasure of a company to deal with and I think it's fantastic that they are committed to making sure I'm getting everything I want before they charge me a penny. Good people there.

I also spoke with a very knowledgeable gentleman at George Stevens the other day who recommended this tension head: George Stevens Manufacturing Inc.
That dancer arm concerns me a little. Anyone ever try one of these for pickup bobbins?


...and in the back of my mind I keep thinking, "Most of the big winders are just using felt. Give up on this idea." I have to try just a little more though. I'll know when to quit. So far I'm $0 out of pocket on this quest so why not, right?

[copperheadroads]

Tension is like a German Shepherd ,Underestimate it or turn your back on it & it will bit you on your ass .

[ReWind]

FYI - I've found that a smaller diameter whisker disk works better with some of my spools. The excessive overhang was part of my problem.

Regarding the Azonic tensions system, I switched to a model with a lesser range of tension, removed a part from the tension head to lower the total moving mass, and found a wire path that actually allows for just a little slip at the initial startup jerk and things are running very well with it now. I've gone through about 10 bobbins at full speed/high tension with my most finicky 42AWG PE spool and it's finally reliable and consistent!

Major thanks to Wes at Azonic for all his patience while I tried various products and setups.