QUALITY MANAGEMENT

Besides the above measuring and monitoring systems, Zumbach offers other instruments, such as on-line profile measuring systems of continuously manufactured profiles of any kind, X-ray measuring systems for CV lines, combined diameter and eccentricity measuring systems for communication cables and more.

Wall thickness scanning

Zumbach has also introduced brand new ultrasonic wall thickness scanners. Thanks to their completely new patent pending design, the transducers incorporated in new UMAC Z50 and UMAC Z100 scanners can be synchronously adjusted to the best possible measuring position within seconds (motorized upon request). The scanners cover an outside diameter range from 5 to 100mm (0.2" to 4"), depending on the model. They represent a smart and simple solution for fully noncontact, in-line wall thickness measurement of cable jackets, tube and hose. In combination with the proven Wallmaster data acquisition, processing and display system from Zumbach, a full process control can additionally be accomplished.
Advantages and benefits of the UMAC Z50 and UMAC Z100 include easy and fast product changes, quick and easy symmetrical positioning of all transducers (centrally adjustable), four and six-point measurement availability, large measuring range, no readjustments of transducers needed, fully non contact uncritical centering, 100% construction from non corrosive materials for maintenance-free long-life underwater operation, extreme compactness for installation into cooling trough directly after the extruder, automatic control and easy centering.

Laser diameter measurement

The new ODAC 60 and ODAC 100 laser diameter measuring heads are based on Zumbach’s vast experience, gained over many years of designing and manufacturing diameter gauges. Both are manufactured with modular designs, and they are available with a support rail or as an individual emitter and receiver. The ODAC 60 and ODAC 100 heads have a maximum measuring field of 60 mm (2.4") and 100mm (3.9"), respectively, and they can also be installed in constricted confines or several emitter/receiver pairs can be mounted in the same plane. The heads are offered with a complete range of accessories and interface units for optimal integration into almost any process and thus can be used for all products. Options, such as diagnostic output, input/output for synchronization of multiple ODAC measuring heads, calibration standards, limiting support and splash guards are offered, and different versions are available to work with different processors and interfaces. Both heads deliver 1000 scans per second (2000 is optional) and high precision and they feature compact and rugged design, flexible mounting, the availability or special beam geometries (narrow or parallel) and different measuring modes: diameter, gap, penetration and multiple measurements.
The ODAC 100 is available in multiple versions, e.g. the “J” version for the connection to any USYS data acquisition and display unit from Zumbach or models with built-in processor like:

Diameter and ovality measurement

– the RS version which communicates via the integrated RS interface with a higher level system, like USYS Multiline from Zumbach, host computer or PLC
- – the DP which communicates via the integrated Profibus DP interface with a higher level system
- – the EN version which features an Ethernet port and TCP/IP protocol for the data transfer through existing networks such as LANs and others.
- – the JS versions are best suited for the synchronization of multiple measuring heads, allowing thus e.g. a measurement in several axes or a dual scanning configuration for large product dimensions.
- – the N versions with a special beam geometries, e.g. narrow beam for contour measurements and more

Multi-tasking controllers

The new ODAC 63TRIO system is based on Zumbach’s vast experience, gained over many years of designing and manufacturing optical diameter gauges. The ODAC 63TRIO measuring head supplements the program of three-axis laser measuring systems with a measuring field of 64mm (2.52"). The principle for the ODAC 63Trio is the same as for the smaller model ODAC 33Trio, which pioneered synchronous three-axis measurement. Since commissioning the first system, three-axis measurement has been hugely successful. The accurate detection of out-of-round condition, regardless of the orientation of the product ovality in combination with reliable and fast diameter measurement as well as other valuable functions are features that no ODAC Trio customer should do without.
Advantages include synchronized measurement axes on one single plane, ultra compact design, reliable detection of mean value regardless of the orientation of the product ovality, accurate computation of circumference and cross section, increased measurement accuracy and reliability, integrated fault detector that offers three times higher detection certainty and sensitivity than two-axis models and available interfaces including J standard for USYS, RS-232/-422/-485, Profibus DP and Ethernet.

Total on-line quality control

New versions of the well-proven USYS family of multi-tasking controllers have been introduced: the economical USYS 200 for one-point measurement and two multi-sensor systems: the USYS 2100 for up to three measurement sensors and the six-sensor USYS 8100. All three reflect many new features and improvements for comprehensive on-line measurement, control and quality monitoring. Diameter, ovality, eccentricity and capacitance can be measured, and additional sensors for faults, line speed, events, etc., can be integrated. All faults can be logged and identified, and a complete status display of the parameters continuously informs the operator on the performance of the production line. Some common features on the new controllers include an operator interface with choice of languages, menu-driven context-sensitive software keys, a faster and more efficient software platform, a bright high-resolution LCD TFT screen and unlimited number of product recipes. The flexible configuration of the USYS controllers, with process specific intelligence from the extensive Zumbach software library, provides optimal adaptability to suit the process and production line. These systems can be used in many wire and cable production lines including core and jacket extrusion, foam and foam-skin extrusion, cold rolling and wire drawing. Typical configurations are Jacketmaster for core and jacket extrusion, Cellmaster for foam and foam-skin extrusion and Wallmaster for single or multi-layer wall thickness measurement. Each system manages and monitors quality and production costs by simultaneously carrying out many functions (multitasking). These functions include continuous measurement and display, monitoring of limit values, control and material savings, recipe management, statistics and data logging and communication with a computer.

Sigma-Expert control and CpK-Pilot

Zumbach has the solution for all quality parameters. USYS systems process measurement data from a variety of sensors and communicate with the user and with host computers. Among many other functions, USYS processors also control extrusion lines or other manufacturing lines with intelligent self-adapting controllers, Sigma-Expert and CpK-Pilot.
Intelligent, self-adapting system for dynamic control. With CpK-Pilot the target value will automatically be optimized to the lower specification limit. This translates into important material savings.

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