Innovations for quality control and process optimization

The wire 2018 will take place from April 16 to 20, 2018, in Düsseldorf and again, SIKORA will present innovative measuring, control, inspection, sorting, and analysis systems from its extensive product portfolio.

On the exhibition booth 9A41, with a space of 200 m² (240 y²) on two levels, visitors can discover the most recent technological innovations for quality control and process optimization for the wire and cable, optical fiber as well as plastics industries.

X-ray technology measures diameter, wall thickness, and concentricity for the medium and high voltage cable production

A highlight at the SIKORA exhibition booth is the X-RAY 8000 NXT – the worldwide industrial standard for quality assurance of medium, high and extra-high voltage cables in CV lines. It measures the concentricity, wall thickness, diameter, and ovality of up to three layers of XLPE and EPR isolated cables during production.

Measuring values for the centering of the injection tools and control are available immediately after the starting of the line. The multi-sensor technology (MST) and two high-speed scanners ensure a reliable online measurement. With each single scan, the MST measures the movement of the cable, compensates vibrations and provides double the number of measurements.

Measurement of wall thickness, concentricity, diameter, and ovality in jacketing lines

For continuous quality control during the insulation or jacketing of conductors and cables, the X-ray measuring devices X-RAY 6000 as well as X-RAY 6000 PRO are recommended.

Both systems precisely provide reliable measuring values regarding diameter, wall thickness, concentricity as well as ovality for a reproducible product quality. Layer thicknesses of any kind of material are measurable. A maximum of productivity is achieved by the automatic control of line speed and extruder rpm.

Diameter measurement on the highest level

In extrusion lines, the devices of the LASER Series 2000 and LASER Series 6000 are indispensable components for a diameter measurement on the highest level. Furthermore, the classic and high-end devices are used in rewinding lines for the wire drawing.

They stand out by their high precision and continuous functionality without calibration or maintenance times. Due to up to 5,000 measurements per second/per axis, the LASER Series 6000 impresses with the highest single value precision for an efficient line control. The integrated lump detector function ensures a detection of irregularities on the product surface of transparent and non-transparent materials.

In addition to standard interfaces, the device series provides OPC UA, and therefore, is best equipped for “Industry 4.0”.

Safety for every cable production

SIKORA offers a complete program of direct current (DC), high frequency (HF) and alternating current (AC) spark testers. Already during the extrusion, the insulation of wires and cables is tested with the high voltage testing devices and possible insulation faults are detected and documented in a timely manner.

Further application areas are rewinding lines. For the testing, the dry cable running through the bead chain electrode of the spark tester is exposed to the selected test voltage. Therefore, faults in the insulation are reliably detected.

Measurement of concentricity, diameter, and ovality

With the CENTERVIEW 8000, SIKORA presents a measuring system for the non-contact, online 8-point-eccentricity, 4-axes-diameter and 8-point-ovality measurement of coax cables, LAN cables as well as automotive and installation cables to the global public.

Technical highlights of the CENTERVIEW 8000 are the graphic visualization of measuring values as a scatter plot that shows the distribution of short-term variations as well as the automatic positioning of the gauge head to the cable position for highest reliability. A further feature is the measurement of micro-coax cables with a diameter range from 0.1 to 10 mm (0.004 to 0.4”).

Online quality control of optical fibers in the drawing tower

By means of a drawing tower model, SIKORA presents live its broad portfolio of measuring systems for quality control of optical fibers at different positions. There will be systems presented for the measurement of the diameter and the position of the naked and coated fiber as well for the determination of the tension.

Furthermore, gauge heads are displayed for the measurement of the fiber temperature at the hot position of the drawing process, to determine the fiber temperature for the control of the furnace, and at the cold end, to exactly dose the Helium used for the cooling, and therefore, to save costs.

In addition, a gauge head for the measurement of the concentricity of the coating as well as for the detection of lumps on the surface of the coated fiber is exhibited.

Online inspection and sorting of XLPE and semiconductor pellets

A further highlight at the wire is the PURITY SCANNER for online inspection and sorting of plastic pellets that are used for the insulation of medium, high and extra-high voltage cables as well as onshore and offshore cables.

The unique combination of an X-ray camera with an optical camera system is currently the only technology that reliably detects contamination on the surface as well as inside of plastic pellets. Contaminated pellets are automatically sorted out.

Offline inspection and analysis of pellets, flakes, and films/tapes

SIKORA engineers developed the PURITY CONCEPT Systems for small material throughputs and applications where sample testing or an incoming goods inspection is sufficient. These analysis devices are alternatively equipped with X-ray technology, optical cameras or infrared sensors and detect contamination in pellets, flakes, and tapes.

For example, the PURITY CONCEPT Systems are used to analyze pellets that have been detected and sorted out by the PURITY SCANNER. Another typical application is the testing of tapes that are used when manufacturing factory joints.

The interplay of online and offline inspection and analysis provides an absolute control of the material purity as well as the development of a database to further improve processes and avoid future contamination.

Further devices at the SIKORA exhibition booth

• LUMP 2000: Measuring technology for the detection of lumps and neckdowns in two or three measuring planes with double sensor technology
• ULTRATEMP 6000: Non-contact temperature measurement of the polyethylene melt
• CAPACITANCE 2000: Innovative capacitance measurement with multi-zones technology as well as integrated FFT and SRL analysis
• Display and control systems: Powerful ECOCONTROL 6000, 1000, and 600 processor systems as well as low-cost display and control devices REMOTE 2000 and DISPLAY 2000

Diameter and ovality measurement of steel tubes by means of millimeter waves based radar technology

The SIKORA S-WAVE 6000 is based on progressive, high resolution radar technology and represents an innovative alternative to the optical triangulation technology. The advantage of radar technology is that reliable measuring values are generated even under difficult environmental conditions. Therefore, the automotive industry uses in the area of autonomous driving radar technology guaranteeing reliable measuring values under all weather conditions.

The S-WAVE 6000 measures online and contactless, simultaneously from several directions the diameter and ovality of steel tubes. In addition, in this way fast rotating steel tubes can be precisely measured. The system requires neither coupling media nor a calibration. The temperature of the tube has no influence on the measurement. Due to the slim design the S-WAVE 6000 can easily be integrated in the production process in arbitrarily large distance to the tube.

The S-WAVE 6000 is even able to provide reliable measuring values when the tube moves outside the center of the measuring head. The technology is suitable for blank, rough as well as cold or warm surfaces.

Thickness measurement of steel plates by means of millimeter waves technology

Radar technology based on millimeter waves additionally convinces with the measurement of the thickness of steel plates. Similar to the optical triangulation method the distances to the steel plates are measured at the top respectively at the bottom.

The advantage is that the radar waves are directed over a reflector on the product to be measured, thus the radar transceivers carry out the measurement from a protected position. Dust, steam and even dripping water do not influence the measuring result. For this application as well, surface quality is no issue with the result that blank, rough, cold and warm surfaces are precisely measured.
 
Wall thickness measurement of plastic coated steel tubes by means of X-ray and millimeter waves technologies

At the Tube SIKORA also showcases systems for the measurement of plastic coated tubes on the basis of X-ray and millimeter waves technologies. A plastic coating is among others applied at freely installed, underground and under water laid steel tubes for corrosion protection. For the joining of produced tubes compliance with specified dimensions for example for the wall thickness is essential.

Therefore, for the measurement of the wall thickness of the plastic coating, SIKORA‘s X-ray based X-RAY 6000 PRO for tubes with a diameter up to 200 mm is used. For larger dimensions the previously described S-WAVE 6000 is used. Both methods are independent from the material of the product to be measured and the temperature, they do not require coupling media and no calibration.

Immediately with the online measurement precise measuring values are accessible. These are visualized at the monitor of the processor system ECOCONTROL 6000 and allow the operator, if required, to intervene in the process for optimization. Thus, SIKORA systems are essential components to ensure the highest quality and an efficient process during the manufacturing of plastic coated steel tubes.