Measuring and control technology for hose and tube extrusion lines

Transcription

1 Measuring and control technology for hose and tube extrusion lines

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3 5 Content Introduction 4 1 LASER Series LASER Series 2000 XY models for dual-axis diameter measurement LASER Series 2000 T models for triple-axis diameter measurement LASER Series 2000 PROFIL for round and flat profiles 2 LASER Series LASER 6020 XY, LASER 6040 XY, LASER 6080 XY for high-speed diameter measurement and surface inspection from 2 measuring axes 8 ECOCONTROL 600/1000/2000/ Premium processor systems with 8.4, 15 or 22 -TFT color monitor and touch-screen operation Automatic diameter/wall thickness control Hot/Cold module HC 2000 VIRTUAL REMOTE/DISPLAY Visualization and control of the production data 3 TIGER LASER 6010 XY 9 For diameter measurement and high-speed surface inspection 4 X-RAY 6000 PRO/BASIC 10 X-ray measuring system for wall thickness, eccentricity and diameter measurement of single-layer and multi-layer products Automatic crosshead centering 4/6-point wall thickness, inner/outer diameter and ovality measurement including fault detection Measurement of ultra small diameters 5 LUMP axis lump and neckdown detectors 3-axis lump and neckdown detectors 6 LENGTH Length measuring system for hoses and tubes 7 ULTRATEMP Ultrasonic temperature measurement system for the measurement of PE-melts

4 4 Introduction Since 1973 the German based SIKORA AG has been setting the standard worldwide as manufacturer of premium measuring and control devices for the hose and tube as well as wire and cable industry. Modern Laser and X-ray technologies measure precisely and reliably product parameters such as eccentricity, wall thickness, inner and outer diameter and ovality. Interesting is also the temperature measurement by means of ultrasonic and the length measurement by means of an image analysis. Integrated into the extrusion line these measuring devices increase quality, profitability and process efficiency of the production. A continuous calculation of production data helps avoiding wall thickness over sizes. The hose and tube manufacturer consumes less material while achieving a more efficient material usage. Every micrometer of plastic material that can be saved by the use of measuring and control technology makes the production more economic and protects at the same time the scarce resources. SIKORA is headquartered in Bremen, Germany. Here the high-quality devices are developed and manufactured. Regarding service and sales SIKORA is globally active with offices in Brazil, China, France, India, Italy, Japan, Korea, Russia, Turkey, the Ukraine, USA and the United Arabic Emirates. 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. Since 1993 SIKORA has been meeting the requirements according to DIN EN ISO The certification confirms SIKORA 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 team in research and development is working continuously on the development of new technologies that help manufacturers of hoses and tubes to run their extrusion lines more efficiently and to remain competitive.

5 5 1 LASER Series 2000 Having the process under control at any time LASER Series 2000 XY LASER Series 2000 XY-models for 2-axis diameter measurement LASER Series 2000 T-models for 3-axis diameter measurement LASER Series 2000 F/R-models for the measurement of flat and round profiles LASER Series 2000 T Typical features high precision and reliability no moving parts no calibration MTBF of 15 years The LASER Series 2000 includes measuring devices for the measurement of the diameter of hoses or tubes in 2 or 3 planes. Directly integrated in the production line the gauge heads are characterized by precision, reliability and functionality. The technical base of these gauge heads is a state-of-the-art CCD-line sensor technology combined with laser diodes as light sources and intelligent powerful analysis software. The outstanding feature of the non-contact measuring technology is the extremely high single value precision, which is an important aspect for the calculation of the standard deviation. The short exposure time assures reliable readings at all common line speeds. Product vibrations have no influence on the measurement. There are no guide rollers needed. The gauge heads of the LASER Series 2000 are free from moving parts and have a nearly unlimited life cycle. Even after years of operation the devices measure as precise as on the first day of delivery. Due to the optical measuring principle without any moving parts, the Mean Time Between Failures (MTBF) of this series is 15 years. Calibration or maintenance procedures are not necessary. Swivel gauge head function

6 64 Specific measuring systems for your application LASER Series 2000 XY With the LASER Series 2000 XY SIKORA offers gauge heads for a precise diameter measurement in 2 planes. The diameter is calculated by diffraction analysis directly from the shadow image. LASER Series 2000 T SIKORA s LASER Series 2000 T SIKORA provides a precise triple-axis diameter measurement, including the minimum/ maximum values, the ovality and its orientation. The ovality is accurately calculated independently from the orientation of the minimum and maximum values to the 3 measuring axes. Intelligent design Interesting is the design of the LASER Series 2000 devices. The smaller gauge heads are equipped with a unique and proven multi-slot protection. The gauge heads for bigger measuring ranges as well as all triple-axis devices are open at the bottom, which prevents water and dirt falling into the gauge head. A special feature of the larger models is the swivelling gauge head design, which allows the head to be moved up and out of the extrusion line. The measuring heads are free from wearing parts, remain with high precision throughout their lifespan and do not require any calibration or maintenance. LASER Series 2000 PROFIL The solution for the reliable online-measurement of flat and round profiles is the LASER Series 2000 PROFIL. It provides an exact measurement of the width and the height, respectively the diameter. The fascinating technology of the gauge head requires no rotation and thus no maintenance. Technical data LASER Series 2000 Product name Product diameter Accuracy Repeatability Exposure time LASER 2005 XY mm ± 0.25 μm ± 0.1 μm 0.2 μs LASER 2010 XY/T mm ± 0.5 μm ± 0.1 μm 0.2 μs LASER 2025 XY/T mm ± 1.0 μm ± 0.2 μm 0.2 μs LASER 2030 XY mm ± 1.0 μm ± 0.2 μm 0.2 μs LASER 2050 XY/T mm ± 2.5 μm/± 1.0 μm ± 0.5 μm 0.2 μs LASER 2100 XY/T mm ± 5.0 μm ± 1.0 μm 0.2 μs LASER 2200 XY mm ± 10 μm ± 1 μm 5.0 μs LASER 2300 XY mm ± 20 μm ± 1 μm 5.0 μs LASER 2500 XY mm ± 50 μm ± 2 μm 5.0 μs LASER 2030 PROFIL mm (round) Profiles: ± 5 μm 1.0 μs mm (width) Round: ± 1 μm mm (height) LASER 2050 PROFIL mm (round) Profiles: ± 10 μm 1.0 μs mm (width) Round: ± 2.5 μm mm (height) Measuring rate 500/ s (higher measuring rates on demand) LASER 2005 XY: 1,200/ s Interfaces Serial interface RS485, Setup and diagnosis interface RS232, optional analog interfaces, Profibus-DP or alternatively industrial field busses such as CANopen, Ethernet/IP, DeviceNet, ProfiNet Power supply V AC ± 10 %, 50/60 Hz

7 57 2 LASER Series 6000 A milestone in diameter measurement W-LAN (WiFi) ready LASER Series 6000 LASER Series 6000 for high-speed diameter measurement and detection of lumps and neckdowns The gauge heads of the new LASER Series 6000 combine a variety of new technological features for the highest precision and reliability to improve productivity of the production line sustainably. 2,500 measurements per second, all with extremely high single value precision, allow for an optimum line control and provide reliable statistical data. The gauge heads measure the diameter of hoses and tubes with an impressive precision and repeatability. SIKORA offers 3 gauge head models for product diameters from 0.2 to 78 mm. Integrated display and automatic diameter control in the gauge head The devices include an integrated LCD display with control panel. This provides the operator with diameter values at one glance, directly at the measuring device. At the control panel the diameter nominal value can be entered and the control module activated. Via line speed or extruder rpm the module controls the diameter automatically to the specified value. Typical features Wide gauge head opening Up to measurements per second Integrated lump detection function Integrated LCD Display with control panel Universal interface module for all connections Optimum feeding and protection of the connection cables W-LAN interface SIKORA App Lump detector function The high measuring rate of the diameter devices also allows for the detection of lumps and neckdowns. With the two-inone system investment costs are reduced. In addition, there is more space in the line as only one gauge head has to be installed. LASER 6040 XY with integrated display and control panel

8 48 Interfaces Directly integrated in the gauge heads is a universal interface module for all connections such as RS485, RS232, Profibus- DP or alternative industrial field busses such as CANopen, Ethernet/IP, DeviceNet, ProfiNet. As the interface module as well as all connectors are completely integrated in the gauge head, they are perfectly protected against dirt, water or mechanical influences during the production. Gauge head design The opening of the gauges is twice as big as the measuring range to ensure an easy product feed through. A special feature is the swivel type gauge head. It allows for the gauge head to be easily moved up out of the extrusion line. The measuring heads are open at the bottom to prevent dirt and water from falling into the measuring area. The feeding of the connection cables to the interface module is protected, directly in the gauge head stand. LASER 6040 XY on a comfort stand W-LAN Interface The LASER Series 6000 has common interfaces as well as an optional WLAN-interface, which allows for a direct connection to a smart phone or laptop. The W-LAN-interface is used for diagnosis and quality control. Measuring values, trend and statistical data, but also video signals are transferred. SIKORA App SIKORA offers a free app for displaying measuring values, trends, statistics or video signals at smart phones. The operator can easily log in via the W-LAN interface and receives immediately production data of the particular gauge head at the smart phone. The app allows also the calibration of the gauge head. The values of the test probes are read by a QR code and the measured values listed in a log file, ready to W-LAN transfer to the QM department. SIKORA App for LASER Series 6000 Technical data LASER Series 6000 Product name Product diameter Accuracy Repeatability Exposure time LASER 6020 XY mm ± 0.2 μm ± 0.1 μm 0.2 μs LASER 6040 XY mm ± 0.5 μm ± 0.2 μm 0.2 μs LASER 6080 XY mm ± 1.0 μm ± 0.5 μm 0.2 μs Measuring rate 2,500 measurements/s 5,000 measurements/s for LASER 6020 XY (option) Interfaces RS485, RS232, LAN (Ethernet); optional: W-LAN (WiFi), Profibus-DP, analog interface or alternatively industrial field busses such as CANopen, Ethernet/IP, DeviceNet, ProfiNet Power supply V AC ± 10 %, 50/60 Hz

9 59 3 TIGER LASER 6010 XY Today s fastest XY surface inspection TIGER LASER 6010 XY Visualization of a fault TIGER LASER 6010 XY for diameter measurement and high-speed surface inspection The TIGER LASER 6010 XY is an innovative two-in-one measuring device. It measures the diameter and provides at the same time the fastest surface inspection for lumps and neckdowns available today. Optionally, the TIGER LASER 6010 XY can be combined with a device of the ECOCONTROL series for displaying an image of the faults. The images can also be saved on the ECOCONTROL. Due to the visualization hose and tube manufacturers are able to evaluate faults realistically without the cost of a rewinding. The technology is based on 2 high-resolution image sensors. By means of these sensors the surface profile is inspected and faults are reliably detected. The high measuring rate guarantees the highest precision of the diameter measuring results. Typical features Diameter measurement and surface inspection Use of image sensors Graphical display and storage of the surface profile of detected lumps and neckdowns High fault detection probability Technical Data TIGER LASER 6010 XY Product diameter 100 µm to 10 mm Diameter accuracy ± 0.5 μm Min. detectable fault length 0.1 mm Min. detectable fault height ± 0.5 µm Line speed up to 3,000 m/min Measuring frequency Diameter: 500 Hz Lump detection: 512 khz Interfaces RS485, RS232, LAN (Ethernet) Line speed input Optional: Universal Interface Module, Profibus-DP, 2 digital contacts for lump and neck, analog IN for tolerance specifications, analog OUT for diameter values 2 x 16bit Power supply ± 10% V AC, 50/60 Hz

10 X-RAY 6000 PRO/BASIC Intelligent partner at the extrusion of hoses and tubes X-RAY 6120 PRO with ECOCONTROL 6000 X-ray measuring system for wall thickness, eccentricity and diameter measurement In extrusion lines, in which hoses and tubes are produced, the X-ray measuring system X-RAY 6000 provides an online quality control directly at the production process. Continuous compliance with product specifications regarding wall thickness, eccentricity and diameter is assured. Single layer or multi layer hoses, aluminium composite tubes, pressure hoses with textile reinforcement, small or large diameter hoses made of PE, HDPE, PVC, EPR as well as foamed products, products made of EPDM, nylon, rubber, silicone are reliably measured by the X-RAY Moreover, it is suitable for quality control of medical or cosmetic tubes. Depending on requirements (hot or cold measurement) the X-RAY 6000 is installed in any position in the production. Immediately with the online measurement the measuring values of the wall thickness, eccentricity, inner and outer diameter and ovality are available at the processor system ECOCONTROL The eccentricity measuring values are displayed at 8 points and allow the operator for an optimal centering of the extrusion tools. The use of the X-RAY 6000 as measuring head at the hot end, directly after the extruder or after the first vacuum tank/cooling section allows for a fast centering and automatic control of the line speed or the extruder rpm. An additional diameter gauge head after the vacuum tank/cooling section combined with a HotCold-Control considers the material shrinkage. At the vertical, 22 wide-screen monitor of the X-RAY 6000 PRO production data are clearly displayed

11 11 5 X-ray measuring technology for single- and multi-layer products The X-ray measuring systems X-RAY 6000 are fascinating in general and in detail. Customers who need to measure up to three material layers during production, choose the X-RAY 6000 PRO. For hose and tube extrusion lines where only one product layer shall be measured, the X-RAY 6000 BASIC is available. X-RAY 6000 BASIC for single-layer products The X-RAY 6000 BASIC measures the wall thickness, the eccentricity, and the inner and outer diameter of single-layer hoses and tubes. In particular, in production lines where only the outer layer needs to be measured, the X-RAY 6000 BASIC is interesting. The production data are clearly displayed at a 7 monitor, which is integrated directly in the measuring system. The operation is intuitive via touch screen. In combination with the processor system ECOCONTROL 600, 1000, 2000 or 6000 an automatic control of the line is possible. By controlling line speed or extruder rpm the product parameters are controlled to the nominal value. X-RAY 6035 BASIC with integrated 7 monitor. The BASIC device is an economic and at the same time powerful alternative to the X-RAY 6000 PRO and provides exactly the functions that are of importance for quality control. For hoses and tubes where only one material layer needs to be controlled, the X-RAY 6000 BASIC proves to be an efficient and reliable partner. Typical features X-RAY 6000 BASIC Measurement of the wall thickness, eccentricity, the inner and outer diameter and ovality of single layer products Automatic control of the line speed and extruder rpm under consideration of the minimum values (in combination with the processor systems ECOCONTROL 600/6000) Selectable measuring rate from 1 to 3 Hz Integrated monitor for measuring value display Intuitive touch-screen operation No calibration X-RAY 6120 PRO with 22 monitor.

12 412 X-RAY 6000 PRO for multi-layer products The X-RAY 6000 PRO measures the wall thickness, the eccentricity, the inner and outer diameter and ovality of up to 3 different product layers. The system includes as a standard the display and control device ECOCONTROL 6000 with a vertical arranged 22 TFT monitor. It is either mounted directly at the X-RAY gauge head, on a separate stand, or is remotely integrated in the control cabinet of the line control. The ECOCONTROL 6000 is conveniently operated via touch screen and shows all measuring values numerically and graphically as well as trend and statistical data. A line presentation with pictograms of the connected devices provides a clear overview. The PROfessional device becomes most efficient with the already included automatic control of the line speed or extruder rpm under consideration of the minimum values. From the very first day of operation, both X-ray devices, the X-RAY 6000 PRO and the X-RAY 6000 BASIC, underline their power and assure a continuous online quality control at the production of hoses and tubes. Simultaneously, the systems reduce the wall thickness to a minimum value. Quality assurance and the reduction of material lead to a significant increase of productivity. Specific measuring system for individual application X-RAY 6000 TRIAX with 6-point-wall thickness and ovality measurement including fault detection In addition to 2-axis measuring devices SIKORA offers the 3-axis measuring system X-RAY 6070 TRIAX. The X-ray device is especially tailored to the requirements at the production of composite tubes. It measures the wall thickness and ovality at 6 points and detects non-conformities on the inner surface of the tube and at the outside as well. Due to the measuring rate of up to 100 Hz, even the smallest blisters can reliably be detected. X-RAY 6020 for ultra small diameters X-RAY 6020 is suitable for product diameters from 0.65 mm to 15 mm. The device is intended for the area of medical tubes where quality is an essential requirement. The heart of this technology is the development of new proprietary X-ray tubes with directed X-radiation, which allow for a measurement of ultra-thin wall thicknesses. Automatic crosshead centering Specifically for the manufacture of rubber hoses at the extrusion process the X-RAY 6000 PRO/BASIC provides measuring values for automatic wall thickness centering. By using these techniques a manual centering during production is not necessary. In addition, the online concept continuously ensures an optimum hose centering and thus a uniform wall thickness distribution over the entire hose circumference. Typical features X-RAY 6000 PRO Measurement of the wall thickness, eccentricity, the inner and outer diameter and ovality of up to 3 different material layers Automatic control of the line speed and extruder rpm under consideration of the minimum values Selectable measuring rate from 1 to 3 Hz (optional 10, 25, 100 Hz) 22 vertical wide screen monitor Intuitive touch-screen operation No calibration Technical Data X-RAY 6000 PRO/BASIC Measuring principle Non-contact with modern X-ray technology Product name Diameter* Accuracy** X-RAY 6020 PRO mm 5 μm X-RAY 6035** mm 5 μm/ 10 μm X-RAY 6070** mm 10 μm/ 15 μm X-RAY 6070 TRIAX** mm 10 μm/ 15 μm X-RAY 6120** mm 10 μm/ 15 μm X-RAY 6200 PRO mm 20 μm X-RAY 6300 PRO mm 30 μm * measuring ranges up to 500 or 650 mm on demand ** X-RAY 6000 PRO/BASIC Measuring rate X-RAY 6000 PRO: 1 to 3 Hz (optional 10, 25, 100 Hz) X-RAY 6000 BASIC: 1 to 3 Hz Interfaces X-RAY 6000 PRO RS232, USB Option: LAN (Ethernet) X-RAY 6000 BASIC RS485, RS232 Option: LAN (Ethernet) Industrial field busses such as CANopen, Ethernet/IP, DeviceNet, ProfiNet, Profibus-DP Power supply 100V 240V AC, +/- 10% 50 Hz (60Hz)

13 LUMP 2000 Lump-free production LUMP 2000 XY LUMP 2000 T 2-axis lump detectors 3-axis lump detectors For continuous quality control at the hose and tube extrusion lump detectors are just as essential as diameter measuring devices. The 2- and 3-axis lump detectors LUMP 2000 XY und LUMP 2000 T detect the smallest lumps and neckdowns on the product surface precisely and with high reliability. By the use of a powerful signal processor the number, height, depth and length of the fault location are evaluated. The combination of the double sensor technology (differential measuring principle) with infrared light sources assures a reliable fault detection even under difficult conditions such as dirt or extreme vibration. Typical features Highest reliability due to double sensor technology Fault analysis regarding type, dimension, length, number and position Elimination of ghost faults The lump detector is sturdy and can due to its small dimensions easily be installed in every extrusion line. The setting of tolerance thresholds and the visualization of lumps and neckdowns is realized with the REMOTE 2000 or a processor system of the ECOCONTROL series. Alternatively, the LUMP 2000 devices can directly be integrated in the line control via the Profibus interface. Technical data LUMP 2000 Product name Product diameter* Min. detectable size Min. fault length (lumps/neckdowns) LUMP 2010 XY/T mm/ mm 0.01 mm 0.5 mm LUMP 2025 XY mm 0.02 mm 0.5 mm LUMP 2035 T mm 0.01 mm 0.5 mm *For smaller dimensions the FIBER LUMP 6003 is available Line speed up to 3,000 m/min Power supply V AC ± 10 %, 50/60 Hz Interfaces Serial interface RS485, Setup and diagnosis interface RS232, fault contact, analog input for lump/neckdown tolerance, alternatively Profibus-DP (option)

14 414 6 LENGTH 6000 Perfect length LENGTH 6000 Monitor image LENGTH 6000 Length measuring system for hoses and tubes The LENGTH 6000 is a reliable non-contact online length measuring device for strand-shaped products. With the LENGTH 6000 hose and tube manufacturers measure the product length already during production and assure that only the accurate length is supplied or further processed. The technology of the LENGTH 6000 is based on an optical measuring principle. The surface structure on the bottom side of the passing product is defined by two neighbouring CCD-image sensors. The length is measured and the speed is calculated from the correlation of both images. The LENGTH 6000 is equally reliable for all types of strandshaped products with reflective and rough surfaces. The system recognizes automatically whether the product is moving forward or reverse and measures the length always precisely from zero line speed. Typical features Length measurement independent of the product direction (forward/reverse) Measurements start from zero line speed Highest reliability and precision Technical Data LENGTH 6000 Measuring principle Non-contact, optical, comparison of image patterns Product diameter 5 to 180 mm (additional diameters on demand) Line speed Up to 500 m/min (higher speeds on demand) Accuracy < 0.05 % deviation Interfaces Serial interface RS485, Diagnosis interface RS232, Pulse output Optional: LAN (Ethernet), Profibus-DP, Ethernet/IP, ProfiNet etc., all common industrial field busses, alternatively analog output Power supply V AC ± 10%, 50/60 Hz

15 155 7 ULTRATEMP 6000 Ultra strong temperature measurement ULTRATEMP 6000 Ultrasonic temperature measurement system for polyethylene melts With the ULTRATEMP 6000 SIKORA presents an ultrasonic temperature measuring device for the reliable online measurement of the polyethylene melt directly in the flow channel between extruder and crosshead. The melt temperature of the polyethylene, which is used during the extrusion of hoses and tubes, is extremely sensitive. A few degrees decide between a homogeneous and thus optimum melt and the risk of unmelted or burnt material. ULTRATEMP 6000 is a temperature measuring system, which continuously measures the temperature of polyethylene melt precisely, directly before the cross head during extrusion. It works on a non-contact basis. Besides temperature measurement the ULTRATEMP 6000 detects inhomogeneities in the melt. The high measuring rate allows a fast response time as well as the registration of small temperature variations. The system does not influence the melt flow properties, as the ultrasonic sensors are positioned outside of the flow channel. Therefore, melt shear heating effects do not occur. ULTRATEMP 6000 importantly contributes to process optimization and costs reduction in hose and tube extrusion lines. Special editions for the measurement of PVC melts are available. Typcial features Maximization of the extruder output through optimum melt temperature Elimination of unmelted or burnt material Detection of inhomogeneities in the melt Non-contact, no melt shear heating effects Technical data ULTRATEMP 6000 Measuring principle Non-contact, non-invasive temperature measurement based on ultrasonic technology Measuring range 100 C to 180 C Accuracy < ± 1 C Interfaces Serial interface RS485 Setup and diagnosis interface RS232 Profibus-DP, analog output Power supply V AC ± 10%, 50/60 Hz

16 416 8 Partner of the measuring systems Powerful signal processors ECOCONTROL 6000 ECOCONTROL 2000 ECOCONTROL 2000/6000 The power of the ECOCONTROL 6000 processor system becomes obvious by its fascinating combination of its capabilities, attractive design and intuitive operation. All measuring values of the connected diameter and eccentricity devices are in clear focus. Up to 8 measuring and testing devices can be connected to the ECOCONTROL 2000/6000 at once. The measuring values are displayed numerically as well as graphically on a 15 (ECOCONTROL 2000) or vertical 22 TFT monitor with intuitive, menu-driven touch screen operation. A clear line presentation with pictograms of the connected devices provides additional information. Moreover, it contains a time or length-related trend diagram for all values, a graph of the distribution of the single values (statistical distribution curve) and comprehensive statistics with the minimum, maximum and mean value, standard deviation, Cp and Cpk values. ECOCONTROL 1000 The ECOCONTROL 1000 offers two serial interfaces for the connection of measuring devices such as SIKORA s LASER Series 2000 or LASER Series Additionally, two testing devices such as the LUMP 2000 can be connected. The measured values are displayed on a 15 -TFT touchscreen monitor. The ECOCONTROL 1000 also includes a time or lengthreleated (optional) trend diagram of all values, combined with a graph of the distribution of the single values (statistical distribution curve) and comprehensive statistics with the minimum, maximum and mean value, standard deviation, Cp and Cpk values. ECOCONTROL 600 ECOCONTROL 600 offers one serial interface for the connection of a SIKORA measuring device. Additionally, via two digital contacts events from a LUMP 2000 for the detection of lumps and neckdowns can be read. The measuring values are displayed numerically and graphically on a clear 8.4 -TFT-monitor. Also there is a graphical time- or length-related (optional) trend diagram for all values combined with a graph of the distribution of the single values (statistical distribution curve) and statistics with the minimum, maximum value, the mean, standard deviation, Cp and Cpk values. The operation is menu-driven via touch screen. Pioneering Software: Automatic diameter/ Wall thickness control A special feature of all ECOCONTROL models is the control module SET POINT. It ensures 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 1000/2000/6000) With the HC 2000 the material shrinkage is continuously calculated and considered automatically for the control of the diameter and/or wall thickness.

17 17 5 VIRTUAL Intelligent software concept The virtual gauge technology is suitable for all applications, where a fast wall thickness control is required, but where due to the line configuration or the product structure a diameter or wall thickness measurement directly after the extruder is not possible. Reasons could be a lack of space for a hot diameter gauge head or the need for an immediate cooling of the product after the extrusion. In these cases the intelligent software concept VIRTUAL 2000 is the solution: the measuring device is installed at the end of the vacuum tank/cooling section. Up to now, the control of the extruder at the end of the line was very slow. The reason was the big delay time, a result of the low line speeds and the big distance between the measuring device and the extruder crosshead. This delay time is eliminated by the VIRTUAL Already at the start-up of the line an extruder model of the VIRTUAL 2000 calculates the expected cold wall thickness for a defined inner diameter and a predefined material dependin on the specified extruder rpm and the line speed. The VIRTUAL 2000 displays the cold wall thickness even before the product reaches the measuring system at the end of the line. Already during the start-up process the VIRTUAL 2000 controls the required extruder rpm, in order to achieve the cold wall thickness, set by the operator. The control and the regulation of the extruder is done under consideration of the line speed, selected by the operator. There is no need for any shrinkage setting. Technical Data ECOCONTROL Display TFT-color monitor 22 (vertical) ,4 In/ and outputs Serial interface RS485 4 (8 option) 4 (8 option) 2 (4 option) 1 Electrically isolated digital inputs 4 (8 option) 4 (8 option) 4 (option) 4 (option) for the connection to testing devices Analog outputs 16 Bit; V 4 (option) 4 (option) - - or +/- 10 V (unipolar/bipolar) Contact outputs for tolerance and 4 (8 option) 4 (8 option) 4 (option) 4 (option) status messages (max. 30 V, max. 0.5 A) Serial interface RS232 for communication 1 (option) 1 (option) 1 (option) 1 (option) with an external computer USB interface for a printer 1 (option) 1 (option) 1 (option) 1 (option) Electrically isolated input for (option) 1 (option) rotary pulse generators (0 / 15 V) Electrically isolated interface module 1 (option) 1 (option) 1 (option) - for control of the diameter (HC 2000) USB customer interface Profibus-DP as well as alternative field busses Yes (option) Yes (option) No No Ethernet interface (selectable OPC/Suitelink) 1 (option) 1 (option) 1 (option) 1 (option) W-LAN (WiFi) 1 (option) Storage Power supply Hard disk Hard disk Flash disk (option) V V V V (+/-10%) (+/-10%) (+/-10%) (+/-10%) 50 / 60 Hz 50 / 60 Hz 50 / 60 Hz 50 / 60 Hz

18 418 9 REMOTE/DISPLAY 2000 Visualization and control of the production data REMOTE 2000 DISPLAY 2000 Standard display and control device REMOTE 2000 In addition to the innovative measuring and testing systems SIKORA offers compatible display and control devices. The REMOTE 2000 is the basic display and control device and universally applicable for all SIKORA diameter measuring devices. The display of the measuring values is on a five-digit 20 mm high clear LED display. It is perfectly suitable for panel mounting or for installation at the gauge head. LASER Series 2000/6000 in combination with the REMOTE 2000 The REMOTE 2000 can be combined with a diameter gauge head of the LASER Series 2000 or LASER Series The average diameter value of the connected measuring device is clearly displayed at the LED display. Via a control key the average diameter value or the display of the ovality can be selected. The REMOTE 2000 includes a product library for up to 50 hose and tube recipes. Nominal values and tolerances can easily be recalled. In combination with the control module SET POINT an automatic control of the line speed or extruder rpm during the production is ensured. Optionally, a lengthrelated print out of the measuring values as well as statistical data are available. Furthermore, the REMOTE 2000 provides an interface, to support a connection to an external PC for data gathering or PLC line control operations. In this way a targeted and direct control is assured. LUMP 2000 in combination with the REMOTE 2000 In combination with a LUMP 2000, the REMOTE 2000 shows the number as well as the type of faults. Different symbols inform the operator if the fault is a lump or neck down. Lump and neckdown information such as the height, depth and length of the fault are stored, giving the operator the possibility to view previous faults. Typical features REMOTE 2000 Large, clearly arranged display and keypad Easy installation at any distance to the measuring head Automatic control module SET POINT (optional) Serial interface for the connection to a measuring head, computer and a protocol printer (optional)

19 19 5 Basic display device DISPLAY 2000 DISPLAY 2000 is a display unit to be used in combination with SIKORA diameter measuring devices of the LASER Series 2000, the LASER Series 6000 or the lump detector LUMP It is suitable for panel mounting as well as for the installation at the gauge head. The digital display of the measuring value is five-digit and device-specific configurable. Connected to one diameter measuring head, the DISPLAY 2000 shows the diameter values and the ovality. In particular for applications where the measuring systems are connected to a system control via Profibus interface or where a second display is requested, DISPLAY 2000 is an interesting and excellent value supplement. Typical features DISPLAY 2000 Digital display Selectable monitoring parameter (diameter, ovality, lumps/ neckdowns) Installation at any distance to the gauge head Serial interface for the connection to a gauge head Technical data REMOTE 2000 Measuring value display Digital, 5-digit e.g mm Display update Programmable, factory setting 1/ sec. Nominal value/ Tolerance selection Nominal value/ Tolerance selection via key pad (operation guided via a 4-digit LED-display) Product storage Up to 50 product types, comfortable programming via the diagnosis software Technical data DISPLAY digit-display Digit height of 25 mm The bright, big figures are easy to read even from a distance of 12 m Interfaces (Bi-directional serial interface) RS485 Power supply V AC, ± 10 %, 50/60 Hz Tolerance message/ Control action a) in clear text on LED-display b) 4 dry contacts Interfaces RS485 (gauge head), RS232 (printer) Analog output (Option) 0 to10 V, deviation output if not used for control (0 10V according to the deviation output +5V=0) Power supply V AC, ± 10 %, 50/60 Hz

20 Technical data subject to change We are here for you! ISO 9001 QUALITY SIKORA Ros/500/9/12 SIKORA AG Headquarters Bruchweide Bremen Germany Ph.: sales@sikora.net BRAZIL sales@sikora-brasil.com CHINA sales@sikora-asia.com FRANCE sales@sikora-france.com INDIA sales@sikoraindia.com ITALY sales@sikora-italia.com JAPAN sales@sikora-japan.com KOREA sikora@chol.com RUSSIA sales@sikora-russia.com TURKEY sales@sikora-turkey.com UAE sales@sikora-uae.com UKRAINE sales@sikora-ukraine.com USA sales@sikora-usa.com