One of the most common product defects in pressed and drawn wires from metal production are scratches. They inevitably occur during the manufacturing process as soon as, for example, solids get stuck in the drawing die. Scratches in the product often cause the manufactured product to be unusable for further processing.

With the help of our 360° surface inspection, you can reliably prevent these errors and pause production, correct the error, and continue flawlessly.

All highlights at a glance

  • All-round inspection
  • Autofocus
  • Fast detection of defects
  • Flexible and user-friendly software
  • Full recording of production

Measuring head

Robust measuring head for 360° surface inspection

The wire production passes through the measuring head and is analyzed for defects therein. In front of and behind the measuring head are elements for vibration damping of the wire so that it passes through the gauge head as smoothly as possible.

The system supports production speeds of 150 m/min (2.5 m/s) and detects defects within 200 mm. This means that production is stopped after only 200 mm of faulty wire. It is therefore not necessary to rewind the already coiled material.

The connection to the plant control system is possible via a PLC interface module and allows the system to be put into operation fully automatically via the plant and to process the evaluation signals.

Measurement sensors

Our optical measuring sensors capture the wire from all sides and enable the analysis of the wire surface by means of a sophisticated analysis procedure. The system automatically adjusts to different wire sizes and materials, eliminating the need for manual adjustments.

Scratches are measured in their depth, width and length. Scratches are detected from a depth/width of approx. 6 - 10 µm. All detected scratches are visualized in the system and saved at runtime. Even after the end of production, the entire evaluation can be traced and thus the quality of the production can be proven.

Technical data

  • Resolution: 9.2 Megapixel
  • Field of view: 9 x 5.6 mm / 13 x 8 mm (customized to application)
  • Accuracy: 4.6 / 6.8 µm
  • Frame rate: 51 Hz
  • Dimensions (HxWxD): 300 x 300 x 100 mm (measuring head without periphery)

Product management

You can create an arbitrary measurement configuration for each of your products. Here, the system allows you to set the threshold values for the scratch detection for each side of the wire individually. Edge areas of the wire can be excluded from the evaluation if desired.

Archiving of measurement results

The measurement is continuously recorded with date, time and production data. Detected scratches are recorded in detail. When a measurement is re-evaluated, it is possible to see exactly when a scratch was detected, on which side it occurred, and what its dimensions are. In addition, it can be clearly seen at any time which threshold values were used.

Please contact us for further information.