Possible configurations of SIKORA measuring technology in insulating and jacketing lines.
Cable manufacturers are obligated to fulfil customer specifications at the production of cables. These specifications refer to the dimensions of the cable as well as their material or signal transmission characteristics. In order to meet the demands there are measuring technologies used in the lines that continuously monitor cable quality during production.
In insulating and jacketing lines, where for example energy cables or communication cables are produced the X-RAY 6000 helps to permanently comply with the required specifications.
Immediately with the online measurement the measuring values of the wall thickness, eccentricity, outer diameter and ovality are available at the processor system ECOCONTROL 6000. The eccentricity measuring values are displayed at 8 points and allow the operator for an optimal centering of the extrusion tools and controlling of the wall thickness or the diameter to the nominal value. The values are numerically or graphically displayed as cable cross section.
The measuring device is, depending on the application, installed between two cooling trough sections or after the cooling trough. It measures the insulation wall thickness of the material layers as well as the position of the conductor in the insulation. The conductor has to be absolutely concentric in the insulation to assure the mechanical and electrical function of the cable and to minimize the material consumption.
The application field of the X-RAY 6000 ranges from one or two layer insulations, as they are common in the insulating and jacketing area, to RF cables with foamed PE-insulations.
By using an X-RAY 6000 as hot measuring head after the extruder and a diameter measuring head after the cooling trough in combination with a control a constant diameter is achieved. With the hot/cold control module HC 2000 the material shrinkage can be calculated and automatically considered for the control of the diameter or wall thickness.
Besides the X-RAY 6000, which measures the dimensions of the cable, testing and measuring devices are necessary, to assure cable quality regarding material properties. Customers can configure their lines with SIKORA measuring devices tailored to their needs.
The insulation is tested online with spark tester (high voltage spark tester). As a result, possible irregularities in the insulation are detected and documented at an early stage. An implemented quality management system assures that only faultless cables are delivered.
For cables for which the decision is made to run without eccentricity control, the conventional method of the average wall thickness measurement, by the diameter differential calculation is available (see picture right).
Already during the production cable manufacturers can measure the cable length with the help of LENGTH 6000 and assure that precisely the required length of a cable is produced.
A continuous quality control during cable production is precondition for an economic production as risks can be identified and faults can be prevented at an early stage. With the first day of operation SIKORA measuring technology reduces the costs of a production line and contributes significantly to profit increase. The X-RAY 6000 for example pays off already after 4 months.