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CSS 2: Innovative particle detector ensures “thorough“ cleanliness in high-voltage cable production

Absolute cleanliness is the ultimate aim in high-voltage cable production. With the CSS 2 for real time control and detection of contamination in the polymer melt, SIKORA offers a pioneering technology to guarantee process stability and product quality at the production line. With this super clean PE-material, higher voltage insulation strength with identifiable wall thicknesses can be achieved. Thanks to the CSS 2 measuring technology, defect charges, caused by contamination, are a thing the past. Hence, quality standards for high-voltage cables are fulfilled and simultaneously the costs resulting from damages due to inclusions in the insulation are significantly reduced.

No chance for contamination
The innovative camera system CSS 2 detects contamination particles of different size and concentration in XLPE-materials. Contamination can be specifically caused by material handling such as shavings, which are created by wear of the extruder screw. Moreover, the cleaning of the extruder screw leaves dust particles, which bring tiny pores or inclusions into the material. Not to forget contamination in the form of combustion particles such as amber and scorches, which occur during the long-term operation of the line. Contamination in the PE-material creates a considerable risk of breakdown. The CSS 2 eliminates this risk - for higher cleanliness and safety at the production line.

Objective process control and quality assurance
Compared to time-delayed laboratory analysis distant from the production line, the CSS 2 system ensures continuous real-time and online quality assurance. The intelligent system inspects 100% the XLPE-melt for purity in the flow channel and allows an immediate intervention in the production process. The flow channel between the extruder and the cross head includes sight glasses and an optical CCD-camera system which transilluminates the insulation material. The high-resolution CCD-color camera detects particles of 20 µm (0.79 mil) in the PE-melt. The identified constituents are classified with regard to their size. Particles, which exceed the specified tolerance value are analysed by the CSS 2 with highest precision. The particles are displayed graphically with regard to color in its surrounding as well as the vertical and horizontal dimension and the light absorption. Measuring data about contamination are registered on a hard disk for subsequent inspections. Besides the graphical display of the detected particles and its surrounding, monitor pictures show the complete material flow (live image) - even if the selected tolerance level is not exceeded – and a trend curve on the particles per liter. After data analysis the results are presented in a histogram according to size and quantity. With the help of this information the production process becomes superfluous with regard to an optimum material cleanliness. Easily, quickly and precisely the system informs the operator when he can start the production and shows when contaminations exceed the tolerance value and the operator has to intervene in the production process. In contrast to the mere granulate control the system actually detects contamination in the material before the cable is produced. Thus, the CSS 2 concept presents itself as an extremely powerful and efficient partner in the high-voltage cable production.

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