Pressemitteilungen
SIKORA presents the pioneering Virtual Gauge Technology
With the state-of-the-art Virtual Gauge Technology (VGT) SIKORA presents an advanced and unique method to optimize the extrusion process, to minimize the material over-consumption and to simplify the operation of a extrusion line. Now and for the future technologies are needed that quickly and easily provide precise measurements, even under the most extreme conditions and in the smallest spaces. Gone is the day when it was impossible to measure diameter or wall thickness directly after the extruder due to line configuration or product composition.
The concept of the Virtual Gauge Technology
Simulation Technology
Virtual Gauge Technology is the next chapter of measuring technology for the wire and cable sector. This technology developed by SIKORA innovatively controls the wall thickness of the product quickly and precisely at the requested nominal value even though a measurement of the wall thickness immediately after the extruder does not occur. The virtual measurement is still authentic.
Forward Thinking Design
Previously lines with a relatively low haul-off speed could not control the extruder from the end of the line due to the dead time resulting from the distance of the measuring device to the extruder. VGT eliminates this lag time and shows even during the start of the production the expected cold wall thickness despite the product not having arrived at the end of the cooling section. The measuring device is installed at the end of the cooling section for this method. Issues such as contamination, water influence or mechanical load, all of which occur with placement directly after the extruder are eliminated.
The extruder can already be controlled by the VGT during the starting phase to the calculated rpm that is necessary in order to achieve the entered cold nominal wall thickness. The specification of a cold wall thickness value is a decisive advantage over conventional methods where the extruder rpm is entered and as a result a wall thickness value is achieved. The control of the extruder is in consideration of the inserted haul-off speed. The virtual measuring gauge head calculates the extruder rpm to realize the specified wall thickness. The measuring device after the cooling section balances the actual wall thickness against the predicted one and controls the extruder to the requested wall thickness as necessary.
Intelligent Software Concept
The basis of the design is the identification of the extruder through the measurement of its volume output. The volume output is recorded in a user friendly way by the processor system ECOCONTROL 2000. ECOCONTROL 2000 displays the virtual as well as the real measuring value clearly on a 15“ TFT-monitor that can be used per touch-screen. If there are several extruder screws in use, their volume output will also be collected. New material types do not demand an addition of the volume output, but only a short calculation of the material-specific factor with the help of ECOCONTROL 2000. In the event of exceeding the control limit the system informs the operator and gives visual information that he has undertaken a material change that he must notify to the system.
Real advantages
In practice, the VGT is extremely reliable whilst predicting cold wall thickness and guaranteeing accurate control of the extruder. The measuring system at the end of the line measures the real values of the product which are then incorporated into the control. The VGT is compatible with the X-ray measuring devices X-RAY 2000 as well as the laser measuring systems of the LASER 2000 series. It is perfectly suited to application in the hose and tube sector. The virtual measuring head combines typical features of a real gauge head such as precision and reliability with the advantage of technological progress in production efficiency optimization and cost reduction.
