sensoptic

MARCH 2012 • SENSOPTIC SA • 6616 LOSONE • SWITZERLAND • [email protected] • WWW.SENSOPTIC.CH

FAULT DETECTION EQUIPMENT FOR WIRES

SENSOPTIC is a Swiss company specialized in providing innovative optical measuring systems for precision control of surface quality and diameter defects of wires and filaments. We support our customers with the design, process integration and operation of automatic turnkey systems which include proprietary optical PROFILE SENSORS, SENSYSTEM hardware for data acquisition and SENSOFT software for data management and display. Worldwide, our products are successfully used for both on-line production quality inspection and off-line laboratory measurements in various high-end market segments including fine bare wires, magnet wires, precision cables, extruded monofilaments and optical fibers.

PROFILE SENSOR PLD , PSL , PSM and PSD

SENSYSTEM COMPACT, STANDARD and PROCESS


AUTOMATIC QUALITY CONTROL SYSTEMS

Features • Portable system for both on-line and off-line monitoring applications

• Continuous non-contact measurement of wire surface and local defects

• Precision characterisation of lumps, neck-downs, blisters and scratches

• Reliable user-friendly SENSOFT software with real-time data display

• Directly integrated in the production line with Ethernet communication

• PROFILE SENSORS available for single-axis and dual-axis measurements

• Diameters from 0.02 mm to 2.0 mm and line speeds up to 1500 m/min

• Square and rectangular wire profiles with up to 3.0 mm side length

Benefits • Automatic quality certification of manufactured spools before delivery

• Quality control and inspection of purchased spools prior to processing

• Overall improvement of manufacturing process and production yield

• Reduction of costs by minimizing return of goods from customers

• Improvement of filament uniformity ensuring consistent high quality


QUALITY CONTROL SOLUTIONS FOR WIRE PRODUCTION

DISCOVER DEFECTS BEFORE THEY REACH THE MARKET!

lumps · neck-downs · blisters · inclusions · scratches · flaws · insulation breaks


PROFILE SENSOR

Advanced miniaturized optoelectronic

components combined with analogue signal

processing for ultra fast online inspection of

surface faults and short diameter irregularities.

• Photometric measurement

• Continuous IR-LED beams, no laser

• Diameters from 0.01 mm to 3.0 mm

• Line speeds up to 1000m/min

• Real time analogue output signals

• Detection of micrometric defects

• Compact and rugged construction

• Reliable and user friendly

• Optional roller bearing guides

• Not sensitive to wire vibration

• Not sensitive to external light

• No moving parts, low maintenance

• Very low power consumption

SENSYSTEM All hardware for fast data acquisition is

contained in SENSYSTEM units, with input

connections to PROFILE SENSORS and

output USB connection to the PC.

• Hardware for fast data acquisition

• USB 2.0 High speed PC interconnection

• Digital In- and Outputs with opto-coupler

• Integrated PROFILE SENSOR power supply

• COMPACT to connect up to 2 sensors

• STANDARD to connect up to 8 sensors

• PROCESS to connect up to 16 sensors

COMPACT STANDARD

PROCESS

PSD

PSL

PLD


SOFTWARE SOLUTIONS SENSOFT is a data acquisition and data visualisation software specially designed for the

SENSYSTEM. It provides a reliable and user-friendly way of managing from a standard

Windows based personal computer the surface quality of wires and filaments in real time.

• Continuous monitoring of quality parameters in real time

• Intelligent detection of faults beyond specified threshold values

• Automatic data recording and data saving for post-processing

• Elaboration and printing of production statistics and quality reports

• Easy to install on standard PC’s with Windows XP or Windows 7

SENSOFT STANDARD • For laboratory and production

• For lines with equal line speeds

• Continuous data visualisation

• Lump and neck-down graphs

• Automatic indication of wire

surface roughness

• Print function to memorize graphs

and histograms as JPG-file

SENSOFT MULTILINE • For production integration

• Up to 8 lines simultaneously

• For lines with different speeds

• Counts faults over threshold values

• Additional filter functions

• Ethernet ODBC connection for

automatic data exchange with

production machines

• Automatic start/stop synchronization

with winder start/stop


GOOD AND BAD SURFACE QUALITY OF WIRES

The operator inserts in the main menu the nominal diameter, the lump and neck-down

thresholds values and the line speed. A “save” function allows to memorise graphs as

JPG files for documentation. The graphs display the “LU&NE SIGNAL” as a function of

length in meters (blue line for lumps, pink line for neck-downs):

No significant lumps and neck-downs

Low lump and neck-down signal levels: smooth surface

Some lumps in a short section

Smooth surface with random blisters

Many lumps and some neck-downs in a short section

High offset level of lump signal: rough surface with blisters

good quality

regular quality

bad quality

length [m]

length [m]

length [m]

SENSOPTIC S.A. EI PIOPPI 4 SONE TIC.CH [email protected]

MARCH 2012, SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE

DUAL PROFILE SENSOR PSD 100 FOR WIRES

APPLICATIONS

Ultra-fast inspection of surface faults and diameter irregularities for continuous monitoring

of wires in two planes. Industrial quality control applied to drawing, coating, extrusion,

jacketing and colouring processes running at high line speeds. Precision detection of lumps,

neck-downs, blisters, flaws, scratches, coating dropouts, contusions and surface roughness.

FEATURES AND BENEFITS x optical measurement in two planes

x continuous IR-LED light beams

x 100 kHz ultra fast response

x micrometric resolution

x continuous real time monitoring

x analogue output signals

x integrated signal processing

x compact and rugged construction

x precision roller bearing guides

x build-in air insert for dust protection

x reliable and user-friendly

INNOVATIVE CONCEPT Advanced miniaturised optoelectronic components combined with fast analogue signal

processing offer a new dimension in surface fault visualisation. Even at line speeds of

1000 m/min, the Profile Sensor allows accurate measurement and characterisation of

micrometric defects in real time. Thanks to its unique build-in compressed air insert, the

measurements are insensitive to dust and small debris from the manufacturing process.

• VIA D • 6616 LO • SWITZERLAND • WWW.SENSOP • INF

SENSOPTIC S.A. EI PIOPPI 4 SONE TIC.CH [email protected]


DETECTION SPECIFICATIONS

Diameter measuring ranges: 0.10 mm to 0.40 mm

(other ranges available upon request)

Active measuring zone: 1 mm x 1 mm square

Sensitivity at 1000 m/min:

For a fault length of 0.10 mm: minimum fault height change of 6 µm

For a fault length of 0.25 mm: minimum fault height change of 3 µm

ELECTRONICAL SPECIFICATIONS

DC output signals, bandwidth: 0 to 10 V , DC to 100 kHz

AC output signals, bandwidth: r 10 V , 2 Hz to 100 kHz

Lump and neckdown output signals: 0 to 10 V

Supply voltage, power consumption: 18 to 36 V DC , 5 W

• VIA D • 6616 LO • SWITZERLAND • WWW.SENSOP • INF

MECHANICAL SPECIFICATIONS

Housing dimensions (without wire guides): 115 x 115 x 25 mm3

Roller wire-guides: 4 high-speed precision bearings

Dust protection: build-in compressed air insert

Housing and wire-guides material: black anodised aluminium

Net weight: 700 g

PROFILE SENSOR PSL 40 FOR FAULT DETECTION

APPLICATIONS

Ultra fast inspection of surface faults and short diameter irregularities for on-line monitoring

of wires in one or two planes. Industrial quality control applied to drawing, coating,

extrusion, jacketing and colouring processes running at high line speeds. Precision detection

of lumps, neck-downs, blisters, flaws, scratches, bumps, contusions and surface roughness.

FEATURES AND BENEFITS

• diameters from 0.4 mm to 3.0 mm

• optical non-contact measurement

• continuous infrared LED light beam

• detection in one or two planes

• line speeds up to 400 m/min

• detection of micrometric defects

• continuous real-time monitoring

• compact and rugged construction

• reliable and user-friendly

• precision roller bearing guides

INNOVATIVE CONCEPT

Advanced miniaturised optoelectronic components combined with fast analogue signal

processing offer a new dimension in surface fault visualisation. Even at line speeds of

400 m/min, the Profile Sensor PSL 40 allows accurate detection and characterisation of

small defects in real time.

SENSOPTIC S.A. • VIA DEI PIOPPI 4 • 6616 LOSONE • SWITZERLAND • WWW.SENSOPTIC.CH • [email protected]


http://WWW.SENSOPTIC.CH/

DETECTION SPECIFICATIONS

Small diameter measuring range: 0.4 mm to 1.5 mm

Small diameter measuring field: 5 mm

Large diameter measuring range: 1.5 mm to 3.0 mm

Large diameter measuring field: 10 mm

Sensitivities at 400 m/min:

For a fault length of 1.0 mm 10 µm for small range

20 µm for large range

ELECTRONICAL SPECIFICATIONS

Analogue output signals, bandwidth: 0 to 10 V , DC to 40 kHz

Supply voltage, power consumption: 24 V DC , 3 W

MECHANICAL SPECIFICATIONS

Housing dimensions (without wire guides): 170 x 80 x 40 mm3

Housing and wire-guides material: black anodised aluminium

Net weight: 1.2 kg

SENSOPTIC S.A. • VIA DEI PIOPPI 4 • 6616 LOSONE • SWITZERLAND • WWW.SENSOPTIC.CH • [email protected]


http://WWW.SENSOPTIC.CH/

sensoptic

Business

wires sensoptic

sensoptic sa

delivery quality control

quality control solutions

losone switzerland

sensystem hardware

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consistent high quality