WARP Terahertz systems. A new age of product measurement

Transcription

1 WARP Terahertz systems A new age of product measurement

2 2 WARP Terahertz systems WARP Terahertz systems 3 WARP 8 WARP 100 WARP portable For more than 6 years inoex GmbH has placed a special focus on the development and sale of terahertz wall thickness measuring systems for the plastics industry and can justifiably term itself the pioneer of this key technology. inoex has consistently pursued this course and has developed the WARP system featuring transceivers which are able to transmit and receive terahertz waves for a contactless high-precision measurement of wall thickness, diameters and ovality. Low-frequency terahertz rays having wavelengths between microwaves and infrared radiation, offer a high penetration power and thus a multitude of possible applications. inoex has succeeded in developing ever more efficient terahertz transceivers, thus preparing the way for an economic use of low-frequency terahertz technology in the plastics industry. Allow me to introduce myself: I am an innovator Since 1984 we at inoex design the future of extrusion for the best possible market success of our customers, e.g. with WARP 100 for the measurement of 100 % of the wall thickness of a pipe, both in longitudinal and circumferential direction. The fully automated Terahertz system designed for a 100 % measurement of the product wall thickness in the extrusion process, independent of temperatures. MODULAR MEASUREMENT AND AUTOMATION TECHNOLOGY FOR THE EXTRUSION PROCESS. The production of plastic pipes is largely determined by the high demands on quality control, economic efficiency and productivity. These demands can be met only by up-to-date automation concepts. The other important feature is the user friendliness of such measuring and automation systems. The WARP product line solves almost all measuring, automation and documentation tasks for single-layer pipes while offering customized process solutions for very specific pipes. Of particular interest is the easy operation of all WARP systems. This includes, above all, the easy operation of the software, the temperature-independent measuring principle and the automatic centering of the measuring mechanics. WARP systems with their electronically rotating sensors cover a broad product spectrum. Process-oriented automatically centering measuring mechanics combined with gravimetry, thermal centering and other modules provide an affordable complete solution for the automation of pipe extrusion lines. Designed especially for the gas pipe and pressure pipe production, WARP 100 is able to carry out a 100 % wall thickness measurement for pipe diameters of up to 1200 mm (47.24 ). WARP portable is designed for a fast direct measurement independent of pipe temperatures. Reinhard Klose, Founder and managing partner of inoex GmbH

3 4 WARP Terahertz systems WARP Terahertz systems 5 WARP - A NEW AGE OF PRODUCT MEASUREMENT WARP portable - Display WARP 8 WARP 100 WARP PORTABLE wall thickness measurement Version with 8 sensors: WARP 8 measures wall thickness sizes on 8 measuring spots in a highly accurate process. Simultaneously, a direct measurement of diameters is carried out across 4 axes. Very simple operation, independence of pipe temperatures and a fully automated centering procedure are further advantages. Highly precise wall thickness and diameter measurement! 100 % wall thickness measurement: WARP designed for a 100 % measurement, especially of gas pipes and pressure pipes. The system supplies comprehensive product information and is easy to operate due to the automated centering process. 100 % wall thickness measurement for gas pipes and pressure pipes! WARP 21 Terminal WARP portable offers a fast and easy wall thickness point measurement. It is independent of pipe temperatures which makes WARP portable a perfect device for wall thickness measurement in front of the calibration sleeve, specifically for large-sized pipes. The modern ergonomic design offers maximum user convenience. Absolute measurements within seconds including angle display! WARP portable - Display recipe selection

4 6 WARP Measuring principle WARP Measuring principle 7 WARP systems generate a terahertz signal and couple this signal into an open space via a suitable antenna of the transceiver and a focusing optical device. The high-frequency wave spreads into space and is reflected by the measured pipe. Through an antenna of the transceiver the resulting signal is then again coupled into the receive path for respective analysis. Algorithms are used to determine the delay difference between the reflected waves and thus to receive information on product dimensions. WARP wall thickness measurement Wt WARP technology uses a THz chip of the latest generation as terahertz source. It is suitable for all standard plastic materials such as PE, HDPE, PP, PA6, PA12, PVC, etc. ø A b Wt 2 ø A = b - Wt 1 - Wt 2 Wt 1 ø A =outer diameter b= distance sensors NEW MEASURING PRINCIPLE FOR THE HIGHEST MEASURING ACCURACY! Only a steady, continuous and overall stabilization of the extrusion process allows an efficient production process and thus ensures competitiveness in the plastics market. This requires a technology which is able to master the decisive functions measurement & control and their perfect interaction and the related real documentation. Against this background, a new product called WARP was designed. Several transceivers which are distributed around the circumference of the pipe transmit and receive terahertz waves in the lower terahertz frequency range and use them for a contactless measurement. Calculation of the delay time of the reflections provides information on wall thickness, diameter, ovality and eccentricity of the product. Measurement of the runtime of electromagnetic waves is also known under the abbreviation RADAR (Radio Detection and Ranking). ELECTROMAGNETIC SPECTRUM RADIO WAVES MICRO WAVES TERAHERTZ INFRARED RADIATION VISIBLE SPECTRUM ULTRAVIOLET RADIATION X-RAYS GAMMA-RAYS MEASURE: Wall thickness for up to 62 positions 100 % wall thickness measurement Layer thickness Exterior and interior diameters Eccentricity Ovality Mass throughput (with gravimetry) CONTROL: S-min (wall thickness/haul-off) Wall thickness profile (thermal centering) Diameter (vacuum) CONTROL WITH GRAVIMETRY: Weight per length (haul-off/extruder) when combined with gravimetry Thin points (wall thickness/haul-off) Working point (extruder/haul-off) Component dosing Coextrusion 1 Assumption of a known refractive index. WARP diameter measurement WARP 100 % wall thickness measurement

5 8 WARP 8 WARP 8 9 HIGHLY PRECISE WALL THICKNESS AND DIAME- TER MEASUREMENT OF 8 MEASURING POINTS! BENEFITS: Comprehensive product information (wall thickness, diameters, eccentricity, ovality) Absolute measurement Automatic centering Independent of pipe temperatures Maintenance-free Material savings of 5 % or more through s-min control or thin points control, improved centering process and a systematic start-up of the extrusion line Documentation for submission to the customer Proven control principles Easy connection to extruder control Easy to use, thus low training needs WARP 8 sensor distribution + XY cross table Type Pipe dimension [mm] Pipe dimension [inch] WARP 8 / WARP 8 / WARP 8 / WARP 8 / WARP 8 / 250 MAJOR SAVINGS POSSIBLE. MEASUREMENT, CONTROL AND EVALUATION BY WARP 8: Raw material costs amount to a significant proportion of 80 % or more in the total production costs of plastic pipes. Depending on the throughput rates of an extrusion line, the used kind of material and the specified standards, an enormous savings potential lies in the difference between minimum and maximum permissible pipe dimensions. The use of an appropriate measuring and control technology, such as e.g. WARP 8 combined with continuously operating gravimetric systems, offer a savings potential of 5 % or more in used material. EASY TO USE. Of importance for the success of a measuring and control system is not only the savings potential but also an easy operation. WARP 8 is able to set a new standard here. The automatic centering by way of an XY cross table and the fact that no dimensioned components are required simplify enormously the process of setting the system into operation. Another strong point is the user-friendliness of the visualization software. All the line operator has to do is select a pipe recipe and start the measuring process. RELIABLE DETECTION OF SAGGING. On account of the 8 measuring points of WARP 8, the system is able to safely detect sagging at the critical points. Further, the operator receives measuring data on diameters, ovality and eccentricity across 4 axes. WARP - 21 Terminal Wall thickness measurement on 8 measuring points Diameter measurement across 4 axes Automatic calculation of the refractive index (mono-pipe) S-min control (without gravimetry) Alarm handling Documentation and itrend When combined with gravimetry: Thin point control Mass throughput control Weight per length control via haul-off or extruder Wall thickening

6 10 WARP 100 WARP % WALL THICKNESS MEASU- REMENT FOR GAS AND PRESSURE PIPES! MEASURING CYCLES ROTATE ELECTRONICALLY AROUND THE MEASURED OBJECT AND CARRY OUT A 100 % INS- PECTION. WARP 100 represents a technological quantum leap for pipe measurement. The system is able to comply with the need for higher quality demands in view of product safety, size accuracy, complete proof of quality and a reliable product traceability. WARP 100 inspects 100 % of a pipe wall thickness in both lengthwise and circumferential direction. All of this up to a line speed of 60 m/min ( ft/min). The core parts of WARP 100 are the intelligent WARP transceivers developed by inoex. These transceivers subsequently transmit and receive terahertz signals and evaluate the recorded data afterwards by way of algorithms. Any automation system available on the market is not only assessed by its measuring quality but also by its comfortable operation, handling and reliability. Due to its independence of temperatures, the automatic centering via XY cross table and the easy operation of the visualization software, WARP 100 is able to meet these high demands entirely. BENEFITS: Comprehensive product information (wall thickness, diameters, eccentricity, ovality) 100 % wall thickness measurement Absolute measurement Automatic centering Independent of pipe temperatures Maintenance-free Material savings of 5 % or more through s-min. control or thin points control, improved centering process and a systematic start-up of the extrusion line Optimum support for the operator Traceability of the product Documentation for submission to the customer Proven control principles Easy connection to extruder control Easy to use, thus low training needs MEASUREMENT, CONTROL AND EVALUATION BY WARP 100: Type WARP 100 Measuring principle 100 % wall thickness measurement Pipe dimension [mm] Pipe dimension [inch] 100 % wall thickness measurement Diameter measurement across 31 axes (WARP 100 / 1200) Automatic calculation of the refractive index (mono-pipe) S-min control (without gravimetry) Alarm handling Documentation and itrend When combined with gravimetry: Thin points control Mass throughput control WARP 100 / Weight per length control via haul-off or extruder WARP 100 / Wall thickening WARP 100 / WARP 100 / WARP 100 / 630 WARP - 21 Terminal

7 12 WARP portable WARP Process visualization 13 THE SOLUTION FOR DIRECT MEASUREMENT WITHIN SECONDS! WARP portable and display wall thickness measurement INDEPENDENCE OF PIPE TEMPERATURES AND RELIABLE PERFORMANCE. WARP portable is a mobile terahertz based hand-held system specifically designed for medium and large-sized extruded pipes. The battery-operated handheld device offers a fast and easy wall thickness point measurement of plastic pipes having a wall thickness of 6 mm (0.236 ) or more, measuring precision is 50 µm ( ). The modern economic design of WARP portable offers maximum user convenience. Measuring results are displayed on an LCD display by pushing only one button. WARP portable and the respective centering aid just need to be placed onto the pipe and the button must be pressed. VISUALIZATION! EASY INTEGRATION. The future-oriented and platform-independent concept allows visualization as a website by way of an easy integration via browser. As such, the inoex user interface is displayable on all web-enabled devices. The multi-touch surface allows an intuitive navigation through gestures (zooming, wiping). Operation is carried out by way of installed widgets. On the interface, the user is free to configure, add or remove the widget s size or information value, just as he wishes. As such, the user has constant access to his most important applications (favorites). WARP portable which is low-maintenance is supplied with a data logger including timestamp and the measuring position on the pipe circumference, data transfer via WLAN or USB directly to a Smartphone, Tablet or PC. Further advantages are the splash-proof housing (IP 54) and the long battery life of approx. 10 hours. WARP - 21 Terminal BENEFITS: Comprehensive product information (wall thickness) Data logging including timestamp and measurement position on pipe circumference Data transmission via WLAN or USB to Smartphone, Tablet or PC Measurement in just seconds Direct measurement independent of temperatures Exchangeable centering aids Low maintenance Robust, splash-proof housing (IP54) Easy to use FAST CUSTOMER SUPPORT VIA TEAMVIEWER: Direct global support via remote control Easy configuration, no VPN gateway Adherence to the highest safety standards SCOPE OF DELIVERY: Two exchangeable centering aids, one for large diameters, the other for medium-sized pipes Delivered in a robust plastic case Long battery life of approx. 10 hours WARP portable - Scope of delivery

8 14 IDM, itrend Payback 15 IDM - THE INOEX DATA MANAGER! ENORMOUS SAVINGS POTENTIAL! LOGGING, ANALYSIS AND EVALUATI- ON OF YOUR PRODUCTION DATA. WARP systems offer not only an excellent price-performance ratio but also very short payback periods. Depending on mass throughput rates and production time, payback may even be within a few months. itrend - Trend chart example I The inoex data manager (IDM) features a central data logger for the collection of all process and quality data of all standard inoex systems along the extrusion line. The software is installed on a virtual machine on an existing server in your network which means that no additional hardware is required. The analysis and evaluation of your data is carried out by the integrated itrend function. Data can be downloaded for further processing, e.g. as CSV file. BENEFITS: Access to all relevant product data Visualization and data evaluation by itrend Older systems can be addressed by an additional gateway Supports quality assurance Easy access via web browser WARP 8 Ø 250 mm (PE-PIPE; WARP with 8 sensors) Output Production time Savings Material costs Savings p.a. 500 kg/h 16 hrs/day x 350 days/year 2.0 % (WARP) 1.20 /kg 67, kg/h 16 hrs/day x 350 days/year 3.0 % (Gravimetry) 1.20 /kg 100, % total 168,000 WARP 100 Ø 630 mm (PE-PIPE; WARP with 19 sensors) Output Production time Savings Material costs Savings p.a kg/h 16 hrs/day x 350 days/year 2.0 % (WARP) 1.20 /kg 161, kg/h 16 hrs/day x 350 days/year 3.0 % (Gravimetry) 1.20 /kg 241, % total 403,200 itrend - Trend chart example II itrend. itrend visualizes your production and process values in the form of diagrams. Display of process data and time periods can be individually adapted by the user. Besides pre-defined diagrams the user-friendly software offers customized presentations of process values. Storage as CSV files permits the easy export of protocols for documentation purposes for the customer. Operation of itrend is intuitive and it is done via web browser on PC, notebook or tablet in your network. WARP portable (Ø 1200 mm PE; weight per length 54,6 kg/m; recycling costs 0.46 /kg) Produced pipe length up to sellable pipe Scrap Recycling costs per line start Costs for energy, personnel, etc. Costs per line start without WARP portable 2 x 9 = 18 m kg with WARP portable 2 m kg Savings through WARP portable per line start

9 GERMANY inoex GmbH Phone.: Fax: UNITED KINGDOM inoex office UK Phone: Fax: TURKEY inoex office Turkey Phone: Fax: CHINA inoex Ltd. Phone: Fax: USA inoex LLC Phone: Fax: inoex GmbH All rights reserved. Reproduction in total or in parts without explicit written approval by the copyright owner is prohibited. inoex GmbH reserves the right to change a product or to terminate its production at any time without prior announcement and without any obligation. Errors or technical changes excepted. Revised March info@inoex.de