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Measurement of inner cross-section geometry with ProfilControl 7 ICSM: New inline system from Pixargus is the first to also measure the rate of recycled material

Würselen, Germany, March 2019: ProfilControl 7 ICSM from Pixargus keeps an eye on maximizing the rate of recycled material in cut plastic profiles produced by co-extrusion. The inline inspection system illuminates the complete internal geometry of the profiles and measures the coating layers and wall thicknesses in a continuous process. In this way it is possible to maximize the use of recycled plastics in profile cores. As a result, production becomes more cost-efficient and the products more sustainable.

Today’s high-grade recycled plastics are suitable materials for use in the cores of high-tech profiles. While being virtually just as robust and long-lasting as virgin plastics, recycled plastics are more favourable in terms of cost efficiency and life cycle assessment. This is because recycled plastics can be produced with less energy – reducing the CO2 footprint – and they are relatively low-priced. ProfilControl 7 ICSM (PC7 ICSM) is the first system able to measure the rate of recycled plastics in extrusion processes.   

Highly specialized measuring algorithms: up to the limits of the feasible
In order to get a grip on the inside geometry of profiles, Pixargus has merged special measuring algorithms into an entirely new measuring concept. Highly specialized algorithms measure not only the coating layers and wall thicknesses, but also the rate of recycled material used. “It has now become possible to increase the rate of recycled material in profile production up to the ultimate limit because the rate is being continuously checked as the profile leaves the cutter,” explains Michael Frohn, Sales Manager at Pixargus. The ICSM system is already being used for the inspection of cut window and metal profiles. It is also the solution of choice for the inspection of extruded hoses and tubes, where it can be used in place of conventional ultrasonic measuring systems.

100 percent inspected: faults can be corrected in real time
PC7 ICSM is the first inline gauge measuring the inner cross-section geometry, clamping sections, internal webs, and coating and material thicknesses of cut profiles in extrusion lines directly after the cutting device. Flaws occurring during production can now be detected much earlier and corrected in real time, dramatically reducing out-of-spec production. Another advantage of this innovative technology is that instead of picking random samples, PC7 ICSM checks the inner cross section of all profiles within a batch. “Each profile is 100 percent inspected at each individual cut,” adds Frohn. A test log is automatically generated for each piece of profile. The inspection takes place immediately after the cut. Contaminations of the measured profile in the form of saw dust or deformations caused by hot cutting techniques (guillotine cutting) are recognized with high reliability and masked out.

A smart formula: combine 2 systems and get 3 functions
PC7 ICSM combines ideally with ProfilControl 7 DualVision (DV). The top selling PC7 DV inspects the surface and measures the outside contour of profiles with highest measuring accuracy in one measurement. The combination of two powerful systems leaves no side of the profile uninspected. Arranged ahead of the cutting unit, the DualVision system detects any deviations and anomalies in real time. This allows the production process to be optimized at the earliest possible point in time and minimizes rejects. The ICSM system checks the inner cross-section geometry of the profiles as they leave the cutting unit and also sorts the cut profile pieces into “good” or “bad”, if desired. This guarantees 100 percent quality!

Inline or stand-alone measuring station
PC7  ICSM is available as inline system or as a stand-alone, offline measuring station. For the offline inspection of profiles that come as cut pieces, Pixargus offers automated inspection of the surface and the outside and inside contours of profiles all in one unit.

Perfectly networked  
The inspection system is ready for use in Industry 4.0 environments. It comes with all common interfaces, such as OPC, UA etc, and can be integrated within the closed loop controls of the extrusion line.

IMG 1: Today’s high-grade recycled plastics are suitable materials for use in the cores of high-tech profiles. (©iStock)
IMG 2: Pixargus inspects the inner cross section and the clamping sections of cut plastic or metal profiles in extrusion lines directly after the cutting device and, as a first, also measures the rates of recycled materials in the process.
IMG 3: Highly specialized algorithms measure not only the coating layers and wall thicknesses, but also the rate of recycled material.
IMG 3: With the PC7 ICSM editor it is now also possible to define inside parameters for the profile production process with pinpoint accuracy.
IMG 4: Up to eight high-resolution GigE CMOS cameras measure the inner cross-section geometry of profiles of up to 250 mm diameter. In combination with an upstream installed DualVision system, it is even possible to inspect surface defects and the outside contour in parallel.