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Wire & Cable
Complete Measurement & Process Control Solutions
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POWER CABLES
The requirements expected from the in-line measurement technology during manufacturing are getting increasingly stringent with all power cables, from installation cables to EHV cables.The thickness, diameter and centricity tolerances of the insulation layers and sheaths are getting increasingly tighter, due to technical and economical factors. At the same time, there is a steady increase in the cable dimensions, in insulation thickness and in the outside diameter.Faulty spots on the surface and in the insulation must be reliably detected and documented.
The instruments are based on the following technologies:
•X-ray,dynamicorstaticforCVlines•Ultrasonicforsheaths•Laserscanningfordiameterandovality• Imageprocessingforsurfacedefects•Sparktestingfordielectric
Zumbach solutions for nearly all processes and cable types:•Extrusionofinsulation
and jackets for round and sector cables
•CVlines,CCV,VCV•Silanelines•Rewindingandtestlines
Diameter,ovality
Surface Quality
Wall thickness, eccentricity
Process control& display
Lumps, neckdowns
Insulationtesting
Diameter,ovality,wallthickness, eccentricity
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COMMUNICATION
Theever-increasingtransmissionrateandnumberofparticipantsallowedbytheworldwide networks require tighter specifications for communication and data cables.
Thishowevercausesmanufacturingdifficulties,especiallyinthein-linemeasurementof critical parameters such as diameter, centricity and capacitance.Itisalsonecessarytoreliablydetectfaultyspots.Withthein-lineFFT(FastFourierTransform)itisevenpossibletopredicttheStructuralReturnLossordetectprocessproblems.Withverysmallcabledimensionsandhighspeeds, therequirementsfromtheprocessandfromthemeasuringtechniquebecomeevenhigher.
Zumbach solutions for measurement, process, control and data communication:•Conductorextrusion,
solid or foamed•SheathextrusionofLANcables•Sheathextrusion,
telecommunication cables•Rewindingandtestlines
Diameter,ovality,eccentricity
Capacitance
TemperatureWall thickness, eccentricity
Conductor preheatingLumps, neckdowns
Insulationtesting
Diameter,ovality
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Process control& display
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Special cables are to be found in the fields of high temperature, safety engineering, chemistry, automotive, aeronautics, shipbuilding, robotics, superconductivity,medical technology miniaturization and many more. They also require specific in-line measuring solutions taking geometry and materials into account.
Also special shapes such as flat cables, ribbon cables, figure 8 cables, etc., must be tested.Drawn or enamelled conducting wires made of copper, tungsten or from special alloys, with diameters down to 10 microns, require the utmost accuracy while drawing and during the enamelling process.
Zumbach solutions for typical processes such as:•Conductorinsulation•Sheathextrusion•Rewindingandtestunits•Wiredrawing•Enamelling,multiline
SPECIALCABLES&WIRES
Diameter,ovality
Multiline configurations
Wall thickness, eccentricity
Lumps, neckdowns
Insulationtesting
Profile, shape
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Process control& display
Diameter,ovality,eccentricity
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Fibre optic cablesmake very particular demands on the in-linemeasuringtechnique.This is due to the extremely small dimensions of the fibre itself, with tolerances in the sub-micron range when drawing and coating.
A high accuracy must also be maintained with the next processes such as "Loose Tubing" and external jacketing.
Inaddition,localfaultyspotsmustberecognisedateverystage.
Zumbach solutions for nearly all steps of fibre optic manufacturing:•Diameter,ovality,position
when drawing the fibre•Whencoating•WiththeLooseTubingprocess•Whenextrudingthe
external jacket•Formanufacturingtensile
elements made of steel or "Kevlar"etc.
Process control& display
Lumps, neckdowns
Diameter after the first and second coating and after curing
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FIBREOPTICCABLES
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ZUMBACHElectronicswasfoundedin1957inOrpund,Switzerland,whereitisstillheadquartered.ZumbachhaspioneeredmanyachievementsfortheWireandCablemarket,including:
•ODAC® laser scanners with HLF-High accuracy Large Field technology, CSS-Calibrated Single Scan technology, and fast measurement rates.•EXEddyCurrentEccentricityandWallthicknessscannersweretheindustry’sfirstsystemstoprovidein-line measurementsofthesedimensionsandhaveservedastheexperienceforthedevelopmentoftoday'sODEX® system.•CAPAC®,CDR-1capacitancemonitors,andfoamcontrolsystemshasenabledthedevelopmentof today'sCELLMASTER® with build-in FFT and SRL analysis utilized by the communication cable sector.•UMAC®WALLMASTERsystemshaveevolvedtobesuitableforcomplexgeometricshapessuch as multi-layer cables, corrugated cables, concentric neutral cables, and more.
ODaC®
laser Diameter and Ovality Measurement
• Oneofthemostextensiverangeofsolutionsintheindustry• Oneofthehighestcapacitiveloadingcapabilityinthemarket• Electrodesolutionsspecifictomarket,accordingIEC,ULa.o.
• Immunetostrayambientlight• Highest detection accuracy thanks to unique measuring principle
and complex optics solution • Allaxesoperateindependentlyofeachother
•Ultrashortmeasuringtubes:10 mm(0.4 in.) only•Verylownoiselevel•600 Hz bandwidth of the measuring system
• Fullyintegratedsolution.(OuterDiameterandConcentricity)• Insensitivetowirevibrationthankstohighspeedscanning• Automaticinductorcontrolallowsforinstallationintightareas
• Novelconcentrictransduceradjustment• SuperHighRatemodeenablesupto15'000measurements/s• SmartWallalgorithm
• Individualscancalibration• IntegratedLump&NeckdetectiononeveryODAC® • Extensivemeasurementfeatures,including:GapPenetration,Positionetc.
INNOVATIONANDEXPERIENCEINMEASUREMENT,MONITORING&CONTROL
ODeX® Combined Diameter and eccentricity Measurement
UMaC® Ultrasonic Wall Thickness Measurement
KW Surface Fault Detection
Spark Tester Dielectric Fault Detection
CaPaC® Capacitance Measurement
raYeX® X-ray Diameter, Wall Thickness & eccentricity Measurement•Uniquelowradiationmicro-focuspencilbeam•Highestaccuracyandstability,duetonon-ceramiccoatedberyllium protection system and pencil beam technology for dynamic and static models•SimultaneoushighmeasuringratesinXandY
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aUTaC Non-contact Temperature Measurement & Control
Slotted–nothreadingrequired • Fast response • Protectedbywirebreakguard •
WST TeMPMaSTer Conductor Preheating
Variablefrequency=Uniformheating • Wire break detection • Easyaccessandthreading •
SiMaC®
Surface inspection with Machine Vision Upto35'000 scans/s • Min. fault size = 0.1 x 0.1 mm(0.004 x 0.004 in.) • Lengthrelatedscanningandfaultdetection •
PrOFileMaSTer®
in-line Profile & Shape Measurement Lightsectionprinciple • DirectimportofnominalvaluesfromCADdesign • 100%geometrycontrol •
USYS Data acquisition, Processing, Display & Process Control
Extensivenetworkintegrationcapability(availablealsoasblackbox) • Data acquisition solutions • Multiplesensorintegration •
DVW 1 Pivoting Measuring Device for 1 & 2 axis laser Gauges
Economicsolutionforwidthand/orheightmeasurement • Very accurate readings, independent of position and twist • Minimalvaluedetectionoftherelevantdimension •
THECOMPLETESOLUTIONFROMZUMBACH
USYSWebServer
Communication software
Process controlRemote access
Sensors
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ThegoaloftheZumbachGroupistooffertheIndustrythemostcompletelineofmeasuring,processcontrolanddataacquisitionsystems of the highest quality and technology, providingsolutionsforyourentireprocess.
Internet
Customer network
www.zumbach.com
ZUMB.003.0004.EFEB.10
•All technicaldataaresubject tochangewithoutnotice
•ZUMBACHAgencies Australia,Austria,Brazil,Bulgaria,Canada,Chile,China,Columbia,Czech.Republic,Denmark,Egypt,Finland,Greece,HongKong, Hungary,India, Indonesia, Iran, Israel, Japan,Korea,Malaysia,Mexico,NewZealand,Norway,Pakistan,Philippines,Poland,Portugal,Russia,Singapore,
Slovakia,Slovenia,SouthAfrica,Sweden,Taiwan,Thailand,Turkey,USA,Venezuela.
Switzerland (H.Q.)ZumbachElectronicAGP.O.BoxCH-2552OrpundPhone +41 (0)323560400Fax +41 (0)323560430E-mail: [email protected]
argentinaZumbach Electrónica Argentina S.R.L.Deheza2570Piso1Dto.91429-CapitalFederalBuenos Aires - ArgentinaPhone +54 (0)1147010774Fax +54 (0)1147031406E-mail:[email protected]
belgiumZumbach Electronic S.A.J.P.Ballingslaan1BE-1090Brussel (Jette)Phone +32 (0)24781688Fax +32 (0)24782768E-Mail: [email protected]
brazilZumbach do Brasil LtdaCx. Postal 212CEP13270-000Valinhos /SPPhone +551938296000Fax +551938296005E-Mail:[email protected]
France Zumbach Bureau France 6ruede l'AvenirFR77760LaChapelleLaReinePhone +33 (0)164244631Fax +33 (0)164244626E-mail:[email protected]
China P.r.ZumbachElectronic (Shanghai)Co.,Ltd.Caohejing High-tech Park2F,Building18,No.481GuipingRoad200233Shanghai,P.R.ChinaPhone +86 (0)2154260443Fax +86 (0)2154261151E-mail: [email protected]
South office:Zumbach Electronic P.R. China5A,XiLaiDengShuXiangStreetChang Ching RoadChang An Town523869DongGuanCityGuangDongProvincePhone +86 (0)76985355110Fax +86 (0)76985090978E-mail: [email protected]
Germany ZumbachElectronicGmbHKesselsgasse 2DE-50259PulheimPhone +49 (0)22388099-0Fax +49 (0)22388099-49E-mail:[email protected]
indiaZumbachElectronic IndiaPvt.Ltd.Premdeep3rdFloor,12BSind Hindu SocietyOpp: Manikchand Malabar Hills,Lullanagar,PUNE-411040Phone +912026837949/50Fax +912026837959Mobile+919890100814E-mail: [email protected]
italyZumbach Electronic SrlViaAdua,19IT-21045GazzadaSchianno (VA)Phone +390332870102Fax +390332464605E-mail: [email protected]
SpainZumbach Electrónica S.L.c/. JoséRicart,3ES-08980SanFeliudeLlobregat (Barcelona)Phone +34936669361 /6669550Fax +34936664451E-mail: [email protected]
Taiwan r.O.C. Zumbach Electronics Far East6F,No.264,Sec.6Ming Chuan E. RoadTaipei, Taiwan R.O.C.Phone +886226305530Fax +886226305529E-mail: [email protected]
UK Zumbach Electronics Ltd.Cromwell Business CentreHowardWay,NewportPagnellMiltonKeynes,MK169QS.Phone +44 (0)8707743301Fax +44 (0)8707743302E-mail: [email protected]
USa Zumbach Electronics Corp.140KiscoAvenueMountKisco,NY10549-1407Phone +19142417080Fax +19142417096E-mail: [email protected]
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