Optical fibers and optical fiber cables - SIKORA · PDF file2 SIKORA AG is a leading manufacturer and supplier of innova - tive online measuring, control, inspection, analysis and

Optical fibers and optical fiber cables

Measuring and control technology for the production of

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Introduction ................................................................. 2

1 Measuring technology for the production of optical fibers .......................... 3

1.1 Overview ............................................................... 3 Measuring devices for quality assurance in the drawing tower

1.2 FIBER LASER 6003 .................................................. 4 Diameter measurement after the furnace, before and after the coating 1.3 FIBER LASER 6003 AIRLINE ..................................... 5 Diameter measurement with airline detection

1.4 FIBER LASER 6003 CCE .......................................... 5 Evaluation of the coating concentricity

1.5 FIBER TEMP 6003 ................................................... 7 Measurementofthefibertemperature

1.6 FIBER LUMP 6003/FIBER LUMP 6003 MICRO .......... 8 Lump detection on the surface

1.7 FIBER ECOCONTROL ........................................... 10 Premium processor system for visualization and control of production data

2 Measuring technology for the production of optical cables in loose tubing, tight

buffering and sheathing lines ..................... 12

2.1 LASER Series 2000/6000 ..................................... 12 2-axis and 3-axis diameter measurement

2.2 X-RAY 6000/6000 PRO ........................................ 13 Eccentricity, wall thickness and diameter measurement

2.3 LUMP 2000 .......................................................... 15 2-axis and 3-axis lump detection

2.4 ECOCONTROL 6000/1000/600 ........................... 16 Premium processor systems for visualization and control of production data

Content

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SIKORA AG is a leading manufacturer and supplier of innova-tive online measuring, control, inspection, analysis and sorting technology for the optical fiber,wire and cable, hose andtube, sheet as well as plastics industries. Worldwide, users of thesemeasuringdevicesbenefit froman increasingquality,profitabilityandefficiency.ModernlaserandX-raytechnolo-gies measure product parameters such as the diameter, oval-ity, wall thickness and eccentricity, precisely and reliably.

Continuous control of production data helps to avoid wall thicknessoversizesandleadstoamoreefficientmaterialus-age. The cable manufacturer consumes fewer resources and achieves amore efficientmaterial usage. Everymicrometerof material that can be saved by the use of measuring and control technology makes production more economical and saves increasingly scarce resources.

SIKORA is headquartered in Bremen, Germany. Since 1973, the high-quality devices have been developed and manufac-tured at this site. When it comes to service and sales, SIKORA isgloballyactivewithofficesinBrazil,China,France,India, Italy, Japan, Korea, Malaysia, Mexico, Russia, Turkey, Ukraine, the United Arab Emirates and the USA. In cooperation with more than 30 local representatives worldwide, SIKORA serves all customer demands with regard to quality, productivity and cost saving. In addition, international service locations assure fast and reliable customer support on site, any time.

Since 1993, SIKORA has been certified according toDINENISO9001.ThecertificationconfirmsSIKORA’s focus on continuous improvement. Customer satisfaction is SIKORA’s primary objective.

Innovation, technological know-how, quality and service are the four pillars of SIKORA’s company philosophy. A strong research and development team continuously works on the development of new technologies, enabling manufacturers of opticalfibersandopticalfibercables,wires,cables,hoses,tubes, sheets as well as raw materials to increase the process reliability,efficiencyandecologicalbalanceoftheirproduc-tion lines.

Measuring technology for the production of optical fibers and optical fiber cables

All over the world, large amounts of electronic data are trans-ferred every day – faster and over longer distances. Data transfer ismainlyviaopticalfibers. Inorder to transmitdatawithout loss, optical fibers have tomeet the highest qualityrequirements. SIKORA offers a complete series of measuring and control devices that are used in the drawing tower during theproductionofopticalfibers.TheFIBERSeries6000moni-tors and controls the entire drawing process and optimizes productivity. SIKORA is known worldwide for its measuring devices for optical cables.

Highlights FIBER Series 6000 - Measurement of the diameter, position, vibration frequency, tension and spinning

- Detection of airlines and temperature measurement atthebarefiber

- Coating concentricity evaluation- Reliable lump detection with double sensor technology and3-axisor6-axismeasurement

Introduction

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1 Measuring technology for the production of optical fibers

1.1 Overview: Measuring devices for quality assurance in the drawing tower

Quality control of optical fibers in the drawing tower isrealized by using innovative measuring and control technol-ogy at the crucial process phases. SIKORA`s gauge heads andprocessorsystemsoftheFIBERSeries6000measureandmonitor the drawing process and increase by means of con-troltheefficiencyoftheproduction.Hence,aconstantlyhighqualityoftheopticalfibersisensured.

At thebeginningof theproductionofanopticalfiber is thepreform. The preform is manufactured by means of chemi-cal vapor deposition and is available as a glass rod with a diameterof30 to200mm. In thefirst step, thepreform inthe drawing tower is heated up in an inductive furnace to a temperatureof2,100°C.Fromthemeltedglass,theopticalfiberisdrawn.Atthispoint,thefibertypicallyhasadiameterof125µm.After coolingdown, theoptical fiber is coatedwith an acrylate layer that is hardened under UV light. The coatingprotects theopticalfiber frommechanicaldamagesandallows thefiber tobebent. For furtherprocessing, thefibersarewoundontoreels.

FIBER LASER 6003 - hot, bare position- Diameter - Tension- Ovality - Position

FIBER TEMP 6003 - hot position- Temperature

FIBER LASER 6003 AIRLINE - cold position(alternatively FIBER LASER 6003)- Diameter - Tension- Ovality - Position- Airline detection - Spinning

FIBER LASER 6003 CCE - cold position(alternatively FIBER LASER 6003)- Diameter - Position- Ovality - Coating concentricity

FIBER LUMP 6003 MICRO (alternatively FIBER LUMP 6003)-6-axislumpdetection- alternatively: 3-axis lump detection (FIBERLUMP6003)

FIBER ECOCONTROL- Processor system for visualization and control of production data-InterfacetoPLC(programmablelogiccontroller)

FIBER TEMP 6003 - cold position- Temperature

Prod

uctio

n flo

w

Preform

Forced cooling

Coating

UV curing

Furnace

Take-up

Capstan

Optical fiber drawing tower

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FIBER LASER 6003

TheFIBERLASER6003isaninnovativedevicefordiametermeasurementofopticalfibers,directlyinthedrawingtower. The unique measuring principle assures an accuracy of 0.05μmatarepeatabilityof0.02μm.2,500measurementsper second with high single value precision and a short ex-posuretimeof1.2μsalwaysguaranteethehighestaccuracy.

The measuring principle is based on diffraction analysis. Us-ing this method, SIKORA has become the worldwide technol-ogy leader. The principle allows a non-contact, optical mea-surement of diameters without moving parts and no need for calibration.

Typically,thefirstgaugeheadisinstalledafterthefurnacetomeasure thediameterandpositionof thebarefiberand tocontrol theprocess.Basedon thevibrationof thefiber, thisgaugeheadcalculatesthetensionatthebarefiberbymeansof a Fast Fourier Transformation (FFT). The single values ofthefiberpositionaregraphicallyvisualizedviatheprocessorsystem FIBER ECOCONTROL, in the form of a scatter plot(seepage10)andareavailabledirectlyatthegaugeheadvia Ethernet.

A second gauge head, before the coating, measures the cold diameter of the fiberandprovides spinning information viaFFToftheovality.Thecontroliscarriedouteitherbythehotor cold measuring gauge head. A second diameter measure-ment follows the coating. At this point, the gauge head option-ally provides information on the concentricity of the coating. In lines, where a second coating is applied, another gauge head is used.

1.2 FIBER LASER 6003 – Diameter measurement after the furnace, before and after the coating

Preform

Forced cooling

Coating

UV curing

Furnace

Take-up

Capstan

FIBER LASER 6003

FIBER LASER 6003 AIRLINE (alternatively FIBER LASER 6003)

FIBER LASER 6003 CCE (alternatively FIBER LASER 6003)

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Installed before the coating, the FIBER LASER 6003 provides measuring values of the diameter. Alternatively, the FIBERLASER6003AIRLINEdetectsthesmallestairlines. TheFIBERLASER6003andFIBERLASER6003AIRLINEarefactory calibrated and keep their absolute accuracy for the entire life-cycle.

FIBER LASER 6003 AIRLINE

1.3 FIBER LASER 6003 AIRLINE – Diameter measurement with airline detection

These gauge heads can be connected via numerous inter-faces to the SIKORAprocessorsystemFIBERECOCONTROLas well as to a line computer.

Coloring linesThediametergaugesoftheFIBERSeries6003arealsotheoptimal equipment for quality control in coloring lines.

Optical fiber with airline

1.4 FIBER LASER 6003 CCE – Evaluation of the coating concentricity

Afterthecoating,theFIBERLASER6003CCE(CoatingCon-centricityEvaluation)definesthecoatingconcentricityinaddi-tion to the diameter values.

The principle is based on the evaluation of the symmetry of the intensity signal recorded by the gauge. Perfect symmetry means perfect concentricity. Increased asymmetry indicates an increased eccentricity. Tolerance levels for a warning and alarm outputs can be arbitrarily set.

As the FIBER LASER 6003 CCE replaces the FIBER LASER6003 within the drawing tower, an additional diametergauge head is not required at this position.

70 µm

FIBER LASER 6003 CCE

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Technical Data FIBER LASER 6003

Product Diameter50-500μmAccuracy±0.05μm*Repeatability0.02μmExposure Time1.2μsMeasuring Rate2,500/secPower Supply100-240VAC±10%,50/60HzInterfacesRS485,serviceinterfaceRS232,LANOptional:Industrialfieldbus(e.g.ProfinetIO,EtherNet/IP,Profibus-DP,CANopen,DeviceNet),4analogoutputs unipolar/bipolar Dimensions150x65x225mm(widthxheightxdepth)Weightca. 3 kg*Inthecenterofthemeasuringfieldof3mm±0.01%ofthemeasuringvalue

Highlights FIBER LASER 6003/AIRLINE/CCE-Highestaccuracyforanoptimumqualitycontrol duringopticalfiberproduction

- Diameter, position, tension, vibration frequency and spinning measurement-Airlinedetection(AIRLINEoption)-Coatingconcentricityevaluation(CCEoption)-Nomovingparts,nocalibration- Availability 99.8 %

FIBER LASER 6003 AIRLINE As FIBER LASER 6003 plus airline detection

Feature: Airline detectionSmallest Detectable Airline: 0.5 μm(diameter)Measuring Rate: 2,500HzDimensions: 150x95x225mm(widthxheightxdepth)

Weight: ca. 4 kg

FIBER LASER 6003 CCEFIBER LASER 6003 plus coating concentricity evaluationFeature: CoatingConcentricityEvaluation(CCE)Dimensions: 150x65x225mm(widthxheightxdepth)Weight: ca. 3 kg

Picture 1: Ray tracing image of a perfect fiber due to perfectly concentric coating

Picture 3: Ray tracing image of an eccentric fiber: cladding displaced and asymmetric primary coating

Picture 2: Diffraction signal of a fiber with concentric coating Picture 4: Asymmetrical diffraction signal of a fiber with eccentric coating

Theopticalfiberisirradiatedwithacoherentlaserbeam.Theincomingraysoflightparallelyhitthesingleopticalfiberlay-ersandarerefractedandreflectedseveraltimesbeforetheyfall on aCCD sensor. At a symmetric optical fiberwithouteccentricity (seepicture1),a symmetric intensitydistributionresults(picture2).Onthecontrary,ataneccentricopticalfi-

ber, where both coating layers in sum are eccentric to the core (picture3),anasymmetricintensitydistributionresults(picture4).Fromthelatter,asymmetryvaluecanbedefined,whichscaleswith the eccentricity.

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FIBER TEMP 6003

1.5 FIBER TEMP 6003 – Measurement of the fiber temperature

TheFIBERTEMP6003isastandalonegaugeforthemeasure-mentofthefibertemperatureduringthedrawingprocess.Thegauge head can be either installed at the cold (measuring range40° to120 °C)orat the hot end (measuring range500° to1,500°C)of thefiber line.With theprecise infor-mationontheopticalfibertemperature,themelttemperaturecanbecontrolledortheforcedcooling(e.g.helium)canbereduced to a minimum, resulting in reduced costs.

TheintegrationoftwoFIBERTEMP6003devicesatthehotrespectively cold position guarantees the compliance with op-timal temperatures for the highest stability of the process.

In combinationwith the FIBER ECOCONTROL, the temper-ature is displayed in real time and visualized in the trend diagram.Besides,theFIBERTEMP6003canbeconnectedwith the plant computer via one of the numerous interfaces.

Display of the temperature in trend diagrams on the FIBER ECOCONTROL

FIBER TEMP 6003 (hot position)

FIBER TEMP 6003 (cold position)

Preform

Forced cooling

Coating

UV curing

Furnace

Take-up

Capstan

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FIBER LUMP 6003

In addition to diameter, tension, airline, coating concentricity and temperature measurement, lump detectors are used for a continuous quality control in drawing towers. The 3-axis testingdeviceFIBERLUMP6003reliablydetectsthesmallestlumps and neckdowns after coating with a length as small as 500μm.

Each surface fault can be found with a report that records the lengthofthefiber,inwhichthefaulthadbeendetected.Thisreport simultaneously includes information on the total number of faults per spool length and the exact dimensions of each fault.

1.6 FIBER LUMP 6003/FIBER LUMP 6003 MICRO – Lump detection on the surface

Power Supply100-240VAC±10%,50/60HzInterfacesRS485,serviceinterfaceRS232,LAN;Optional:Wi-Fi, analogoutputsunipolar/bipolar,industrialfieldbus(e.g.ProfinetIO,EtherNet/IP,Profibus-DP,CANopen,DeviceNet)

Dimensions170x65x265mm (widthxheightxdepth)Weightca. 1 kg

Technical Data FIBER TEMP 6003Temperature RangeCold: 40° to 120 °C Hot:500°to1,500°CProduct Diameter100-500μmAccuracy± 1 °C for the cold endMeasuring Rate100/sec

Preform

Forced cooling

Coating

UV curing

Furnace

Take-up

Capstan

FIBER LUMP 6003/FIBER LUMP 6003 MICRO

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FIBER LUMP 6003 MICRO

The lump detectors are available for product diameters from 100to500μm and can be easily integrated into a new or al-ready existing drawing tower. The lump detectors can be con-nected to the SIKORAprocessorsystemFIBERECOCONTROLor to a line computer.

Coloring linesThedescribedlumpdetectorsFIBERLUMP6003andFIBERLUMP6003MICROareequallyapplicableincoloringlines.

Typical features FIBER LUMP 6003/ FIBER LUMP 6003 MICRO-Highestreliabilitywithdoublesensortechnology-Detectionofthesmallestlumpsfromupto5μmheightand 500 µm (FIBERLUMP6003)respectively 50 µm (FIBERLUMP6003MICRO) length

- Reliable fault analysis regarding height, length, number and position

Forevenhigherqualityrequirements,SIKORAofferstheFIBERLUMP6003MICROthatdetectslumpsandneckdownsfroma lengthof50μmto100%.Theperformanceisachievedby the six measuring axes. Both gauge heads detect faults as smallasof5μm.

A guarantee for the reliable detection of lumps and neckdowns is the SIKORA double sensor technology. In general, the de-tection of lumps and neckdowns is based on the registration of a change in the amount of light that appears because the fault location passes the measuring plane. The FIBER lumpdetectorsFIBERLUMP6003undFIBERLUMP6003MICROdispose of three respectively six measuring axes for a reliable detectionover thecircumferenceof thefiber.Eachof thesemeasuring axes is equipped with a light source and two recei-vingsensors(doublesensortechnology).Thissystemrecogni-zes changes in the amount of light, and thus, analyzes these by means of a differential measurement.

An example:Anopticalfiberwithalumprunsthroughthegaugehead.Atthepositionofalumptheopticalfiberisbigger.Thisre-ducestheamountoflightthatilluminatesthefirstsensor.Atthat moment the second sensor still measures the amount of lightof theperfectfiber.Thedifferentialsignalof thetwo sensors triggers the lump alarm.

Technical Data FIBER LUMP 6003/ FIBER LUMP 6003 MICROProduct Diameter100-500μm

Min. Detectable Fault Height5μm

Min. Fault LengthFIBERLUMP6003:500μmFIBERLUMP6003MICRO:50μm

Speed1 to 3,000 m/min

Power Supply100-240VAC±10%,50/60Hz

InterfacesRS485, service interface RS232,faultcontact;Optional:analoginputtolerance(lump/neckdown)oralternativelyindustrialfieldbus(e.g.ProfinetIO,EtherNet/IP,Profibus-DP,CANopen,DeviceNet)

DimensionsFIBERLUMP6003:280x150x65mmFIBERLUMP6003MICRO:420x274x80mm (heightxwidthxdepth)

WeightFIBERLUMP6003:ca.4kgFIBERLUMP6003MICRO:ca.13kg

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TheFIBERECOCONTROL isanextremelypowerfuldisplayand control processor system, which clearly visualizes the measuring values of the connected measuring devices and lumpdetectorsoftheFIBERSeries6000.

The measuring values are displayed numerically and graphi-callyona15“TFTmonitor.Inaddition,itincludesatime-relatedtrend diagram of all values and a display of the distribution of singlevalues(statisticaldistributioncurve)andcomprehensive

Display of the diameter, position, tension and temperature as well as the number of lumps, neckdowns and airlines

1.7 FIBER ECOCONTROL – Premium processor system for visualization and control of production data

statistics with the minimum, maximum and mean values, stan-dard deviation, Cp and Cpk values. The operation is intuitive and menu-driven via touch screen. Data storage is available.

TheFIBERECOCONTROListhecentralinterfaceforthelinecontrol, with all signals for a control.

Trend

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Statistics

Technical Data FIBER ECOCONTROLDisplay15”TFTtouchmonitorDisplay of the Following Production and Product Parameters-Diameter -Airlines -Opticalfiberpositionwithscatterplotpresentation- Ovality - Vibration frequency - Trend and statistics-Tension -Concentricity -Numberoflumps/neckdowns- Spinning - TemperatureInputs and OutputsUpto4serialinterfacesRS485fortheconnectionofthemeasuringsystemsFIBERLASER6003,FIBERLUMP6003,FIBERTEMP6003(furtherinterfacesoptionallyavailable)4analogoutputs16Bit,unipolar0to10Vorbipolar-10to+10V(optional)4contactoutputsfortoleranceorstatusmessages(max.30V,max.0,5A;optionally8outputsavailable)1communicationinterfaceviaRS232orLAN(optional)1electricallyisolatedinputforrotarypulsegenerators(0/15V)1USBinterface(includedasstandard)aswellasUSBinterfaceforaprinter(optional)1LANinterface(selectableOPCDA/UA/SuiteLink-optional)Additionalinputsandoutputs,e.g.ProfinetIO,EtherNet/IP(optional)Data StorageHDD,USBmemorystickornetworkPower Supply100-240VAC±10%,50/60Hz

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Technical Data LASER Series 2000/LASER Series 6000Gauge Head Product Diameter Accuracy * Repeatability Exposure TimeLASER2005XY 0.05-5mm ±0.25μm ±0.1μm 0.2μsLASER2010XY/T 0.2-10mm ±0.5μm ±0.1μm 0.2μsLASER2025T 0.2-25mm ±1.0μm ±0.2μm 0.2μsLASER2030XY 0.2-25mm ±1.0μm ±0.2μm 0.2μsLASER2050XY/T 0.5-50mm ±2.5μm ±0.5μm 0.2μsLASER6020XY 0.2-18mm ±0.2μm ±0.1μm 0.2μsLASER6040XY 0.5-38mm ±0.5μm ±0.2μm 0.2μsLASER6080XY 1.0-78mm ±1.0μm ±0.5μm 0.2μs LASER Series 2000 LASER Series 6000Measuring Rate 500/sec/axis upto5,000/sec/axis(LASER6020XY) (highermeasuringratesondemand)

Power Supply 100-240VAC±10%,50/60Hz Interfaces Serial interface RS485, setup and diagnosis interface RS232 Optional:Wi-Fi(onlyatLASERSeries6000),analogoutputoralternativelyindustrialfieldbus (e.g.ProfinetIO,EtherNet/IP,Profibus-DP,CANopen,DeviceNet,OPCUA)

2 Measuring technology for the production of optical fiber cables in loose tubing, tight buffering and sheathing lines2.1 LASER Series 2000/6000 – 2-axis and 3-axis diameter measurement

SIKORA’s product range also includes measuring and control technologiesforthecoloringofopticalfibers,theloosetubingor tight buffering and extrusion of the outer sheath of optical cables.

Loose tubing lines/Tight buffering linesForqualitycontrolduringtheproductionof loosetubesandtight buffered cables, SIKORA recommends the use of an ef-ficient 2-axis or 3-axis diameter gauge head of the LASERSeries 2000 or a superior measuring head of the LASER Series6000fordiametermeasurementwithintegratedlump detection.

The LASER Series 6000 has been designed under the as-pect of Industry 4.0. The SIKORA App displays measuring values, trends, statistics or video signals at smartphones. The operatorcaneasilyloginviatheoptionalWi-Fiinterface.Hereceives immediate production data of the particular gauge head on the smartphone, that he can forward to the qual-ity management. In combination with the processor system

LASER 6040 XY with lump detector function

ECOCONTROL600themeasuredvalues,trendandstatisticdataaredirectlyvisualized.WiththeefficientcontrolmoduleSETPOINT,theconnectedECOCONTROLcontrolsthepro-duction process via line speed or extruder rpm.

Typical features LASER Series 2000- Reliable and precise 2-axis or 3-axis diameter measurement -Nomovingparts,nocalibration

Typical features LASER Series 6000- Innovative CCD line sensor technology with high pixel resolution combined with pulse controlled laser diodes

- Measuring rate of up to 5,000 measurements/sec/axis- Detection of lumps and neckdowns- Integrated LCD display to visualize the diameter value-Wi-FiinterfaceandSIKORA App-Nomovingparts,nocalibration

LASER 2010 XY

* ± 0.01 % of the measured value

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Typical features X-RAY 6000/X-RAY 6000 PRO- Measurement of the diameter, the eccentricity and the wall thickness

- Automatic control of the line speed or extruder rpm under consideration of the minimum values (in com-binationwiththeprocessorsystemsECOCONTROL6000/1000/600)-Selectablemeasuringratefrom1to3Hz (optional10/25Hz;onlyatX-RAY6000PRO)

- Intuitive touch screen operation-Nocalibration

X-RAY 6070 PRO

2.2 X-RAY 6000/6000 PRO – Eccentricity, wall thickness and diameter measurement

Sheathing linesOpticalfibercablesofhighqualityrequirethelatestmeasur-ing technology during the manufacturing process. Thereby, theX-ray technologyused in theX-RAY6000/X-RAY6000PRO is by far the most interesting option.

The devices measure the diameter, wall thickness and eccen-tricity during the extrusion process and ensure a reduction of material usage, an optimal line productivity and an online quality control by automatically controlling the wall thickness.

The X-RAY 6000 is specifically designed for single layerproducts* and equipped with an integrated 7” monitor for the graphical and numerical display of the measured values. This operation is intuitively carried out via a touch screen. The high-performancemodelX-RAY6000PROmeasuresupto threematerial layers and provides impressive accuracy.

Includedwithin thedeliveryof the X-RAY6000PRO is theprocessorsystemECOCONTROL6000(optionallyavailableforX-RAY6000) foranautomaticcontrolof the line speedorextruderrpm.Brilliantly,theECOCONTROL6000visual-izes the measuring values graphically and numerically. It pro-vides trend, statistical data and data storage of all measuring values.

Measurement of the average wall thickness according to the differential measuring methodSheathing lines, for which only a limited budget is available, are controlled conventionally without taking into account the eccentricity.Forthis,adiametergaugeheadisinstalledbe-fore and after the crosshead and the average wall thickness is determined by calculating the difference of the diameter mea-suringvalues.SimilartotheX-RAY6000systems,thecontroliscarriedoutviaoneoftheprocessorsystemsECOCONTROL6000/1000. Depending on the requirements, diametermeasuring gauge heads of the LASER Series 2000 or LASER Series6000maybeused.

Hot/Cold Module HC 2000In combination with an additional diameter gauge head, that isusedafter thecoolingsection,aHot-Cold-Controlmodulcontinuouslycalculatesthematerialshrinkageforfinalqualitycontrolandconsidersitforthecontrolofthediameter.Forthismethod, the hot and cold measuring values of the diameter are compared by a speed controlled delay time memory.

Production data is clearly displayed at the vertical 22” wide-screen monitor of the X-RAY 6000 PRO

2 Measuring technology for the production of optical fiber cables in loose tubing, tight buffering and sheathing lines2.1 LASER Series 2000/6000 – 2-axis and 3-axis diameter measurement

LASER 6040 XY with lump detector function

* Alternatively, the X-RAY6000 canalsomeasure the totalwall thickness of

multi-layer products

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””Measuring rateX-RAY6000PRO:1to3Hz(optional10/25Hz)X-RAY6000:1to3Hz Power Supply100-240VAC±10%,50/60Hz,1,200VA Permissable Temperature+ 5 to + 45 °C Interfaces X-RAY 6000 PRO:RS232, USBOptional:industrialfieldbus(e.g.ProfinetIO,EtherNet/IP,Profibus-DP,CANopen,DeviceNet),LAN,OPCDA/UA

X-RAY 6000:RS485, RS232Optional:industrialfieldbus(e.g.ProfinetIO,EtherNet/IP,Profibus-DP,CANopen,DeviceNet),LAN

Technical Data X-RAY 6000/6000 PRO

Measuring Principle Non-contactwithstate-of-the-artX-raytechnology Application* Insulation, tight buffer, loose tube and sheathing lines, coaxandRFcables MaterialPE,PVC,HDPE,foamedplastic,alltypicalpolymers, nylon, silicone and many others Wall Thickness≥0.3-30mmforPE,HPDE≥0.3-2mmforPVC1)

1)ProductswithPVCwallthickness≥2mmand

adiameter>50mmrequireahigherX-raypower

CalibrationTheX-RAY6000/6000PROrequiresnocalibration Safety (Radiation)Radiation measurements by independent experts have revealedthattheradiationoftheX-RAY6000/6000PROis far below limiting values of all international regulations

Diameter

AccuracyX-RAY 6000 PROX-RAY 6000

Sight field

Opening

X-RAY 6035

5 - 30 mm

5 μm50μm

35 mm

100 mm

X-RAY 6070

6-65mm

10μm60μm

70 mm

100 mm

X-RAY 6020

0.65-15mm min. wall: 0.1 mm

5 μm -

20 mm

25 mm

X-RAY 6120

10 - 100 mm**

10μm60μm

120 mm

180 mm

*X-RAY6000PROformulti-layerproducts/X-RAY6000forsinglelayerproductsandtotalwallthicknessmeasurementofmulti-layerproducts

** Expanded measuring range up to 110 mm on request

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2.3 LUMP 2000 – 2-axis and 3-axis lump detection

LUMP 2010 XY

Technical Data LUMP 2000 Min. Detectable Height Product Name Product Diameter Lumps/Neckdowns Min. Fault LengthLUMP2010XY 0.5-10mm 0.01mm 0.5mmLUMP2025XY 0.5-25mm 0.01mm 0.5mmLUMP 2010 T 0.25 - 10 mm 0.02 mm 0.5 mmLUMP 2035 T 0.5 - 35 mm 0.02 mm 0.5 mm

Line Speedup to 3,000 m/min

Power Supply100-240VAC±10%,50/60Hz

InterfacesSerial interface RS485, setup and diagnosis interface RS232, fault contact Optional:analoginputfortolerance(lump/neckdown)oralternativelyindustrialfieldbus(e.g.ProfinetIO,EtherNet/IP, Profibus-DP,CANopen,DeviceNet)

LUMP 2035 T

Loose tubing/Tight buffering linesForreliable lumpdetection in loose tubingor tightbufferinglines,2-axis lumpdetectors from the LUMP2000XY seriesare available as well as 3-axis lump detectors from the LUMP 2000 T series. The 3-axis measuring principle is focused on the detection of punctual faults with a constantly high detec-tion probability. The 2-axis lump detectors are perfect for the detection of larger faults and so-called bamboo rings.

Sheathing linesIn sheathing lines, the detection of surface faults by lump de-tectors are equally important as well.

Typical features LUMP 2000- Detection of lumps and neckdowns in two or three planes-Faultanalysisregardingtype,dimension,length, number and position-Highestreliabilityduetodoublesensortechnology*- Elimination of “ghost faults”**

* See explanation on page 9

** “Ghost faults“arecausedbylightfluctuationsfromtheoutside,andthus,arenorealfaults

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2.4 ECOCONTROL 6000/1000/600 – Premium processor systems for visualization and control of production data

Premium processor systems with 22“, 15“ or 8.4“ TFT color monitor and touch screen operation

Three ECOCONTROL processor systems form the SIKORA premium segment of display and control devices. Intelligent software technology, clear arrangements, intuitive structure and usability are their convincing characteristics.

ChoosetheextremelyinnovativeandpowerfulECOCONTROL6000, the unique ECOCONTROL 1000 or the smartECOCONTROL600.Eachofthesedisplayandcontrolsys-tems exceeds all expectations in their class.

The innovative display of the line including pictograms of the connected devices provides a unique overview, while the numeric and graphic display of the measuring values, trend diagrams and statistics fulfill every wish regarding process visualization.

The22”,15”and8.4”TFTmonitorsand the intuitive touchscreencontroloftheECOCONTROL6000,1000and600processor systems represent an intelligent and cutting edge technology.

Automatic diameter/wall thickness controlIn combination with the control module SET POINT, theECOCONTROL systems deliver quality assurance and costreduction. They ensure a continuous, automatic control of the diameter or wall thickness to the nominal value by controlling either the line speed or the extruder rpm.

Hot/Cold Module HC 2000 (ECOCONTROL 6000/1000)WiththeHot/ColdModuleHC2000,thematerialshrinkageis continuously calculated and considered automatically for the control of the diameter and/or wall thickness.

FFT analysisOptionally, the ECOCONTROL 6000 visualizes periodicalvariationsof theproductparameter fromanFFTanalysisofthe measuring values. This software package was developed with the support of competent partners within the industry. The FFTanalysis leads to transparencyof theprocesses, showsrisks, that are caused e.g. by variations of the diameter, and indicates potential causes.

Vizualization of measuring data on the ECOCONTROL 6000

Advanced software (optional)

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2.4 ECOCONTROL 6000/1000/600 – Premium processor systems for visualization and control of production data

* Depending on the equipment

Technical Data ECOCONTROL 6000 1000 600Display TFTcolormonitor 22“(vertical) 15” 8.4“ (alternatively 15“, horizontal)Inputs/OutputsSerial interface RS485 for the connection to measuring devices 8* 4* 1Electrically isolated digital inputs for the connection to testing devices 8* 4* 4*Analoginputs16Bit,±10V(bipolar) 8* 4* -Analogoutputs16Bit,±10V(bipolar) 8* 4* -Contact outputs for tolerance and status messages 8* 4* 4*(max.30V,max.0.5A)CommunicationinterfaceviaRS232orLAN 1* 1* 1*Interface for printer 1* 1* 1*Electrically isolated input for 1 1* 1*rotarypulsegenerators(0/15V)Electrically isolated interface module 1* 1* -forcontrolofthediameter(HC2000)USB customer interface 1 1 1Industrialfieldbus(e.g.ProfinetIO,EtherNet/IP,Profibus-DP, Yes* No NoCANopen,DeviceNet)LANinterface(selectableOPCDA/UA/SuiteLink) 1* 1* 1* (onlyOPCDA/SuiteLink)Wi-Fi 1* - -

Data Storage Harddisk Harddisk Externalmedia (optional) (optional)Power Supply 100-240VAC±10%,50/60Hz

Data storageThe data storage on a hard disk is a standard for the ECOCONTROL6000. For the ECOCONTROL1000, thisfeatureisoptionallyavailable.FortheECOCONTROL600,an external storage (USB, LAN) is available upon request.Time, length or reel related production reports are available foreachofthethreeECOCONTROLdevices(6000,1000and600).

VIRTUAL 2000 – Intelligent software conceptThe virtual gauge technology is suitable for all applications, which require a fast wall thickness control, but due to line con-figurationortheproductstructure,adiameterorwallthicknessmeasurement directly after the extruder is not possible. Only after the cooling section, that is to say in greater distance from the cross head, the real measurement is done by this technology.

The basis of the design is the simple, but sophisticated idea that an extrusion model knows the volume output of the ex-truder in its different operating conditions to predict with the highest accuracy the value of the produced cold wall thick-ness of a cable. The volume output is recorded once in a user friendly way by the ECOCONTROL 6000 in combinationwith the measuring device.

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