Zumbach Electronic AG

Postfach 93 , 2552 Orpund
Hauptstr. 93 , 2552 Orpund
Switzerland

Telephone +41 32 3560400
Fax +41 32 3560430
sales@zumbach.ch

Trade fair hall

  • Hall 10 / E41
 Interactive Plan

Hall map

K 2016 hall map (Hall 10): stand E41

Fairground map

K 2016 fairground map: Hall 10

Our range of products

Product categories

  • 03  Machinery and equipment for the plastics and rubber industries
  • 03.07  Integrated automation
  • 03.07.001  Process control technique
  • 03.07.001.02  Machine vision systems

Machine vision systems

  • 03  Machinery and equipment for the plastics and rubber industries
  • 03.09  Measuring and test equipment
  • 03.09.002  Measuring and test equipment for mechanical or dynamic properties
  • 03.09.002.01  Thickness gauges
  • 03  Machinery and equipment for the plastics and rubber industries
  • 03.09  Measuring and test equipment
  • 03.09.007  Measuring and test equipment for optical properties

Measuring and test equipment for optical properties

Our products

Product category: Machine vision systems

PROFILEMASTER®

Accurate In-Line Profile Measurement using Light Section Principle and Machine Vision
The dimensions or even the complete cross-section of profiles and pipes made of metal, plastics or rubber must be continuously measured and monitored in the manufacturing process. The PROFILEMASTER® systems from Zumbach represent an accurate and economical solution to the problem. One or up to six laser / camera modules measure the cross section of the moving profile. A powerful PC based processor adds the partial pictures of the cameras made up of straight lines and radii together to yield the momentary cross section of the profile. All relevant dimensions such as width, height, angle and radii are added together to form the full cross-sectional picture. The nominal values for the profile can be directly imported from the CAD construction (as DXF file) which allows easy and problem free programming. Changes in speed and twist within normal limits have no affect on the measurement.

• For all profiles and pipes including steel, metal, plastic, rubber and other materials
• Measures and monitors product geometry continuously
• Displays key dimensions, angles, radii, etc.
• Alerts operator when product is out of tolerance
• Improved process control and CpK
• Scrap reduction Savings on raw material and post processing costs
• Increased product quality = Higher customer satisfaction
• Seamless integration of the PC-based system with your network

Tube, tubing, pipe, profile measurement

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Product category: Machine vision systems

SIMAC®

Surface Quality Inspection System with CCD Cameras & Image Processing from Zumbach
The SIMAC® 63 is a modern surface inspection system for extruded products, like pipe, cable, and hose, where machine vision technology is used consistently. Its hardware and software reflect field experience with the SIMAC® 500 and continuous development over many years.

Products where SIMAC® 63 inspection has a rapid pay back
Rapid pay back can be expected on all high quality products and particularly on products with high safety requirements.
Typical examples are: Hot water pipes, Compound pipes, Gas pipes, Automotive tubing, Rubber hoses, Offshore products, Cables, Glass fibre cables

Advantages

• Easy to use, with a graphical user interface (GUI) of the latest generation
• Touch screen
• Very compact design
• Bright and focused image, sees faults down to 100 μm (.004 in.)
• Up to a line speed of 500 m/min (1640 ft/min)
• LED lighting system
• Length related scanning and fault definition

Tube, tubing, pipe, profile monitoring

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Product category: Thickness gauges

UMAC® RZ

Ultrasonic eccentricity and wall thickness scanners for tube and hose up to ø 65 mm (2.5 in.) diameter.

The UMAC® RZ scanners for ultrasonic measurement represent a smart and simple solution for in-line eccentricity and wall thickness measurement. Measured data acquisition and processing takes place by means of the high-tech processor UMAC® CI from ZUMBACH. The operation and display is realized with USYS IPC WALLMASTER or higher-level systems such as host computers or PLC systems.
Adjusted within seconds: Thanks to the completely new construction (pat. pend.), the transducers can be synchronously adjusted to the best possible measuring position within seconds.

Many advantages
• Easy and simple handling – New product diameter adjustment takes just a few seconds
• Symmetrical positioning of all transducers, centrally adjustable
• Unique product guiding
• Autonomous operation, possible outside the cooling trough / water
• Large measuring range with the same scanner
• 100% manufactured from non-corrosive materials for maintenance-free, long-life operation under water
• Compact design

Numerous Benefits
• Reduced start-up time thanks to early recognition of concentricity
• Important material savings
• Control of the minimum wall thickness
• Extremely compact, for installation into existing cooling trough
• Return on investment within few months

Tube, tubing, pipe, profile measurement

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Product category: Thickness gauges

UMAC® R

Zumbach Ultrasonic Eccentricity & Wall Thickness Scanners for Outside Diameters upt 620mm (24.41 in.)*
Scanners with fixed transducer holder for 4, 6 or 8 measuring points. Ring shaped transducer mounting fixture custom configured for installation into existing vacuum tank. This UMAC® R scanner is installed inside the vacuum tank on to the bulk head separating the first and second vacuum chamber.

*Scanners for other diameter ranges upon request

Tube, tubing, pipe, profile measurement

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Product category: Thickness gauges

USYS WALLMASTER

Ultrasonic Measurement & Control Systems for Eccentricity & Wall Thickness
USYS WALLMASTER data aquisition, processing and display systems combined with UMAC® ultrasonic scanners and ODAC laser diameter gauges from ZUMBACH allow in-line measurements, data acquisition and control during the extrusion of a wide range of products, like tubing, pipe, hoses and cables. Cutting edge digital technology (DSP) opens up measuring solutions for each process and product:
• Ultra thin walls
• Smallest and largest diameters
• Multi-layer products
• Cable isolations and jackets
• Products of irregular geometry

Special products requiring an off-line QC measurement can now be measured in-line and relevant parameters monitored continuously. The diameter can also be measured in a combination with the ultrasonic measurement with certain scanners. In addition, USYS WALLMASTER systems provide for real-time QC data, process monitoring, trending, SPC data, statistical charts etc.

Economic Advantages
• Reduced set-up time
• Raw material savings
• Scrap reduction
• Continuous process monitoring and control
• Fully automated QC and data collection
• Reporting
• ROI within few months

Technical Advantages
• Easy operating
• Automatic calibration
• Digital Signal Processing (DSP)
• Multi-layer measurement (up to 5 layers simultaneously)
• Measurement of thin walls down to 0.05 mm (.002 in.)
• Thick walls up to 99.95 mm (4 in.)
• Product diameters from 0.2 to 350 mm (.008 to 13.8 in.)
• Flexible configuration, even for products of irregular geometry
• Complete process transparency and control

Tube, tubing, pipe, profile measurement

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Product category: Thickness gauges

WALLSTARTER

Economic Processor Solution for UMAC® Ultrasonic Eccentricity & Wall Thickness Measurement Systems
WALLSTARTER is a processor system for data acquisition, processing and displaying of all relevant data from ultrasonic scanners of the UMAC® series from Zumbach. The WALLSTARTER system consists of two components:
– An USYS WALLSTARTER processor / display unit (as table top or 19" rack mount version) for the parameter input and display in graphical and numerical form of the measured data.
– A high-tech UMAC® CI B measured value processor for ultrasonic measurements.

Application: Single layer tubes and hoses of all kinds such as gas and pressure tubes, PE-X tubes, cable conduit tubes, drain pipes, sanitary/heating

WALLSTARTER offers, thanks to its excellent price-performance ratio an ideal solution for quality testing of single layer plastic tubes and hoses. It measures and monitors the compliance to specification of the following product parameters:
• Wall thickness
• Wall thickness distribution
• Eccentricity

Decisive Advantages
• Attractive pricing thanks to minimal equipment for single layer products
• Easy setup and operation
• Shorter start-up times thanks to early acknowledgement of the eccentricity
• Documented quality
• Large choice of ultrasonic scanners – for each product

Complete Systems
Thanks to the wide range of UMAC® ultrasonic scanners, WALLSTARTER can be easily integrated to a complete measurement and processor system, focusing on the specific needs of your individual extrusion process.

Tube, tubing, pipe, profile measurement

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Product category: Thickness gauges

RAYEX® S

Static X-Ray Measuring and Control System from Zumbach
RAYEX® S is a fully new X-ray system based on latest technology and made with top quality. Unconventional solutions reunited in unique advantages, flexibility and high measurement performance:
1. Easy operation
2. High accuracy
3. Reliable operation
4. Longevity, especially of X-ray sources
5. Easy maintenance and service
6. High safety level

Diameter, Wall Thickness and Eccentricity-Measurement up to 80 mm (3.15 in.) Outside Diameter for:


Tubing/Pipe: PVC, PE, PA, Composite Pipes, Automotive, etc.
Hoses: Rubber, Medical, Silicone, PTFE, etc.
Cables: Coax, CATV, Silane, Jackets

Key Features and Advantages

• High stability and accuracy
- Repeatability typically with in ± 0.02 mm (.0008 in.)
- No need for recalibration in general
- No need for material-specific adjustments

• Simple concept and easy to use
- 4 wall thickness points, 2 diameters, ovality
- 2 X-ray sources under 90˚ to each other
- No moving parts
- No water cooling

• X-ray sources
- Extremely robust and stable
- Easy to exchange, no realignment
- Expected lifetime 2-4 years (at 24 h / day)
- No water cooling required

• X-ray safety
- Unique screening concept
- Minimal scatter, no lead necessary
- Outside radiation level meets national and international standards

• For all materials / combinations
- Plastics, foam, rubber, composites (metal / plastics), foamed structures
- Up to 4 layers measurable

• Processing and display
- Well proven USYS processors
- Software on flash disk
- Additional inputs for other servers and speed / length
- Closed loop controller

Tube, tubing, pipe, profile measurement

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Product category: Thickness gauges

ODAC®

Laser Diameter & Dimension Measuring Gauges
Highest accuracy, robustness, reliability and functionality distinguish all the laser measuring heads from ZUMBACH. Known for precision, quality and ease of use the laser measuring heads are among the best of their class. The technological basis considered for these measuring heads is always of the latest cutting edge technology combined with intelligent and powerful measuredvalue processors which facilitate a simple and flexible integration. Our long-standing experience as a pioneer of in-line measuring technology, combined with high production figures result in a product with an excellent
price-performance ratio.
Amongst the outstanding features are features such as single scan calibration (CSS), single scan monitoring and high data rate output of up to 333* data packages per second. The measuring heads can be used with all line speeds. Vibrations during production have no noticeable influence on measurements.

Outstanding advantages
• Very high scan rate (measuring frequency) up to 2500/s
• High precision measurement
• Permanent calibration
• Integrated fault detection function
• Insensitive to dirt
• No safety problems
• High insensitivity to dirt and dust

Adaptive signal processing in the measuring units increase accuracy
All the measuring heads of the ODAC® series have adaptive signal processing (patent DE3111356), which makes subsequent regular re-calibrations superfluous. Only in instances of component exchange or compliance to calibration regulations ISO 9000/9001 etc would recalibration be required.
All the relevant parameters for accuracy are continuously monitored by the measuring system and automatically compensated. This is valid in particular also for possible long-term changes of the behaviour of the scanner motor or the measuring electronics.

Tube, tubing, pipe, profile measurement

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Product category: Thickness gauges

MSD

Diameter & Ovality Gauges
A Novel Kind of Diameter Measurement Based on Linear Sensor Technology.

With the MSD diameter gauges, ZUMBACH introduces a new series of measuring heads for on-line diameter and ovality measurement and control. This new line complements the high-precision laser diameter measuring heads of the ODAC® series. The MSD models achieve their ideal efficiency in terms of price and performance specifically for applications in the cable and plastics industry.
The experience of almost 60 years with on-line and off-line measurement and control technology has led to a product characterised by the most current and sophisticated technology and functionality as well as by the well-known ZUMBACH accuracy and reliability. Thanks to our new MSD* technology (pat. pend.) it was possible to build very compact yet accurate measuring heads.
* = Multi-Source-Device

Applications
The MSD models are suitable everywhere and can be used in all cable manufacturing lines for measuring all kinds of wires and cables. They are indispensable tools in tube and hose extrusion lines for measuring pressure, waste water, heating tubes, etc. as well as all kinds of hoses. MSD devices can also contribute to quality monitoring for cold applications in the steel and metal industry.

Special Features of the MSD Models
• Cost-effective measurement solutions thanks to an ideal ratio between technology, performance and application
• LEDs of different colours provide the lighting of the axes. There is then no interference between measurement axes, even with simultaneous
  measurement – and not even with reflective products
• Built-in external light filters to prevent ambient light affecting the measurement
• Active redundant measurement by means of up to 8 LED sources
• KW function (detection of surface defects)
• Robust, as is everything manufactured by ZUMBACH

Tube, tubing, pipe, profile measurement

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Product category: Thickness gauges

KW Detectors

Lump and Neckdown Detector Series - Fault Detection of the Highest Level
For continuous quality control, lump & neckdown detectors are as important as diameter gauges and spark testers. The new line of KW TRIO detectors capture with the highest accuracy, reliability and velocity, even the smallest lumps and neck downs in wires, conductors, optical fibres, cables, tubes and hoses.
3-axis detectors provide more precise detection of shortterm faults, because very often, in wire and cable products, the fault covers only a limited angle on the product circumference, e.g. small bumps or blisters.

Our lump and neckdown detectors are based on ZUMBACH's experience of almost 60 years in development and production of optical diameter measurement and fault detection solutions. In order to detect product defects quickly and reliably, ZUMBACH offers fault detectors based on the latest technologies to ensure that high quality products can be produced reliably and with the utmost efficiency.

Advantages

• 3 times higher certainty of detection as with models with less axes
• Flexible mounting concept
• Remote operation and display unit
• Micro-processor for intelligent fault analysis and classification
• Integrated air purging of the measuring windows
• Theoretically unlimited lifetime
• Detailed fault log
• Insensitive to stray light

Tube, tubing, pipe, profile measurement

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Product category: Thickness gauges

LSV

Laser Surface Velocimeters - Non-contact Precision Speed and Length Measurement
Precision speed and length measurements are critical for optimization of continuous or quasi-continuous production processes. Proper utilization of these measurements can lead to lower production costs and higher product quality. The ideal sensor must exceed traditional contact encoder performance, increasing reliability and accuracy while minimizing maintenance requirements and material yield.
The LSV Laser Surface Velocimeters have been designed as the ideal next generation sensors for non-contact length and speed measurement. They
provide precise length and velocity data quickly and reliably for both process control and cut-tolength applications.

The LSV 1000/2000 from Zumbach measure reliably on almost any solid surface, whether controlling processes utilizing carbon steel, shiny aluminum or oily sheets, or producing round wire and cable, or manufacturing paper, cardboard or tissue.

Compact, Reliable, Inexpensive and Profitable
• Zero speed, direction detection (only LSV 2000)
• Reduced operating and maintenance costs
• Attractive ROI, fast payback
• All-in-one system, easy integration into production processes and control environments
• Easy to operate and no re-calibration required
• Visible laser for easy alignment in the field
• Robust sensor technology for reliable operation even under harsh conditions, protection classes IP 66 and IP 67
• Fast, state-of-the-art signal processor with powerful command set for efficient system communication via serial or Ethernet interface
• Includes two trigger inputs for additional light barriers or optical switches for high precision edge detection and offset length compensation
• Hardware status signals for remote diagnostic functions available
• User-selectable full quadrature pulse output and interfacing as LAN & RS 422/232

Tube, tubing, pipe, profile measurement

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About us

Company details

Zumbach Electronic AG, a pioneer of on-line measurement founded in Switzerland in 1957, is a leading global manufacturer of precision dimensional measurement, control and data acquisition systems for all plastic, rubber and composite extrusion applications.  The range of solutions includes in-line and off-line laser and optical outer dimensional and diameter measurement and control systems, ultrasonic and X-ray wall thickness and concentricity measurement and control systems, camera and optical surface fault and defect detection systems, camera and laser profile measurement and control systems, laser speed and length measurement systems, and a wide range of related systems used to precisely measure, control and collect data for extruded tube, pipe, hose, filament, rod, profile and shapes, and to inspect surface quality and to detect defects during the extrusion process. Zumbach systems enable manufacturers to improve product quality, reduce material usage and waste, lessen process set-up time, and provide quality control and statistical process control data for the entire production run.

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