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WARP Terahertz systems A new age of product measurement

WARP Terahertz systems - iNOEX€¦ · WARP Terahertz systems WARP 8 Version with 8 sensors: WARP 8 measures wall thickness sizes on 8 measuring spots in a highly accu-rate process

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Page 1: WARP Terahertz systems - iNOEX€¦ · WARP Terahertz systems WARP 8 Version with 8 sensors: WARP 8 measures wall thickness sizes on 8 measuring spots in a highly accu-rate process

WARP Terahertz systemsA new age of product measurement

Page 2: WARP Terahertz systems - iNOEX€¦ · WARP Terahertz systems WARP 8 Version with 8 sensors: WARP 8 measures wall thickness sizes on 8 measuring spots in a highly accu-rate process

WARP Terahertz systems

For more than 6 years iNOEX GmbH has placed a special focus on the development and sale of terahertz wall thickness measuring systems for the plastics industry and can justifi ably term itself the pioneer of this key technology. iNOEX has consistently pursued this course and has developed the WARP system featuring transceivers which are able to transmit and receive terahertz waves for a contactless high-precision measurement of wall thickness, diameters and ovality. Low-fre-quency terahertz rays having wavelengths between microwaves and infrared radiation, o� er a high penetration power and thus a multitude of possible applications. iNOEX has succeeded in developing ever more e� cient terahertz transceivers, thus preparing the way for an economic use of low-frequency terahertz technology in the plastics industry.

The production of plastic pipes is largely determined by the high demands on quality control, economic e� ciency and productivity. These demands can be met only by up-to-date automation concepts. The other important feature is the user friendliness of such measuring and automation systems.

The WARP product line solves almost all measuring, automation and documen-tation tasks for single-layer pipes while o� ering customized process solutions for very specifi c pipes. Of particular interest is the easy operation of all WARP systems. This includes, above all, the easy operation of the software, the tem-perature-independent measuring principle and the automatic centering of the measuring mechanics.

WARP systems with their electronically rotating sensors cover a broad product spectrum. Process-oriented automatically centering measuring mechanics combined with gravimetry, thermal centering and other modules provide an a� ordable complete solution for the automation of pipe extrusion lines. Designed especially for the gas pipe and pressure pipe production, WARP 100 is able to carry out a 100 % wall thickness measurement for pipe diameters of up to 1200 mm (47.24“). WARP portable is designed for a fast direct measurement inde-pendent of pipe temperatures.

MODULAR MEASUREMENT AND AUTOMATION TECHNOLOGY FOR THE EXTRUSION PROCESS.

Allow me to introduce myself: I am an innovator

“Since 1984 we at iNOEX design the future of extrusion for the best possible market success of our customers, e.g. with WARP 100 for the measurement of 100 % of the wall thickness of a pipe, both in longitudinal and circumferential direction. The fully automated Terahertz system designed for a 100 % measure-ment of the product wall thickness in the extrusion process, independent of temperatures.”

WARP 8WARP 100

WARP portable

2 WARP Terahertz systems 3

Reinhard Klose, Founder and managing partner of iNOEX GmbH

Page 3: WARP Terahertz systems - iNOEX€¦ · WARP Terahertz systems WARP 8 Version with 8 sensors: WARP 8 measures wall thickness sizes on 8 measuring spots in a highly accu-rate process

WARP PORTABLE

WARP portable offers a fast and easy wall thickness point measurement. It is independent of pipe temperatures which makes WARP portable a perfect device for wall thickness measure-ment in front of the calibration sleeve, specifically for large-sized pipes. The modern ergonomic design offers ma-ximum user convenience.

Absolute measurements within seconds including angle display!

WARP 21“ Terminal

WARP portable - Display

recipe selection

WARP portable - Display

wall thickness measurement

WARP Terahertz systems

WARP 8

Version with 8 sensors:

WARP 8 measures wall thickness sizes on 8 measuring spots in a highly accu-rate process. Simultaneously, a direct measurement of diameters is carried out across 4 axes. Very simple opera-tion, independence of pipe tempera-tures and a fully automated centering procedure are further advantages.

Highly precise wall thickness and diameter measurement!

WARP 100

100 % wall thickness measurement:

WARP 100 - designed for a 100 % measurement, especially of gas pipes and pressure pipes. The system sup-plies comprehensive product informa-tion and is easy to operate due to the automated centering process.

100 % wall thickness measurement for gas pipes and pressure pipes!

5WARP Terahertz systems4

WARP - A NEW AGE OF PRODUCT MEASUREMENT

WARP 21“ Terminal21“ Terminal21“ Terminal21“ Terminal21“ Terminal

Page 4: WARP Terahertz systems - iNOEX€¦ · WARP Terahertz systems WARP 8 Version with 8 sensors: WARP 8 measures wall thickness sizes on 8 measuring spots in a highly accu-rate process

WARP Measuring principle WARP Measuring principle

Only a steady, continuous and overall stabilization of the extrusion process allows an e� cient production process and thus ensures competitiveness in the plastics market. This requires a technology which is able to master the decisive functions „measurement & control“ and their perfect interaction and the related real documentation.

Against this background, a new product called WARP was designed. Several transceivers which are distributed around the circumference of the pipe transmit and receive terahertz waves in the lower terahertz frequency range and use them for a contactless measurement. Calculation of the delay time of the refl ections provides information on wall thickness, diame-ter, ovality and eccentricity of the product. Measurement of the runtime of electromagnetic waves is also known under the abbreviation RADAR (Radio Detection and Ranking).

NEW MEASURING PRINCIPLE FOR THE HIGHEST MEASURING ACCURACY!

WARP 100 % wall thickness measurement

MEASURE:

Wall thickness for up to 62 positions

100 % wall thickness measurement

Layer thickness

Exterior and interior diameters

Eccentricity

Ovality

Mass throughput (with gravimetry)

CONTROL:

S-min (wall thickness/haul-o� )

Wall thickness profi le (thermal centering)

Diameter (vacuum)

CONTROL WITH GRAVIMETRY:

Weight per length (haul-o� /extruder) when combined with gravimetry

Thin points (wall thickness/haul-o� )

Working point (extruder/haul-o� )

Component dosing

Coextrusion

6 7

WARP wall thickness measurement

Wt

øA

Wt1

Wt2

RADIO WAVES MICRO WAVES

INFRARED

RADIATIO

N

VISIB

LE

SPECTRUM

ULTRAVIO

LET

RADIATIO

N

X-RAYS GAMMA-RAYS

ELECTROMAGNETIC SPECTRUM

TERAHERTZ

WARP systems generate a terahertz signal and couple this signal into an open space via a suitable antenna of the tran-sceiver and a focusing optical device. The high-frequency wave spreads into space and is refl ected by the measured pipe. Through an antenna of the transceiver the resulting signal is then again coupled into the receive path for res-pective analysis. Algorithms are used to determine the delay di� erence between the refl ected waves and thus to receive information on product dimensions.

WARP technology uses a THz chip of the latest generation as terahertz source. It is suitable for all standard plastic ma-terials such as PE, HDPE, PP, PA6, PA12, PVC, etc.

1 Assumption of a known refractive index.

øA = b - Wt

1 - Wt

2

øA =outer diameter

b= distance sensors

b

WARP diameter measurement

Page 5: WARP Terahertz systems - iNOEX€¦ · WARP Terahertz systems WARP 8 Version with 8 sensors: WARP 8 measures wall thickness sizes on 8 measuring spots in a highly accu-rate process

WARP 8 WARP 8

MAJOR SAVINGS POSSIBLE.

Raw material costs amount to a signifi cant proportion of 80 % or more in the total production costs of plastic pipes. De-pending on the throughput rates of an extrusion line, the used kind of material and the specifi ed standards, an enormous savings potential lies in the di� erence between minimum and maximum permissible pipe dimensions. The use of an appro-priate measuring and control technology, such as e.g. WARP 8 combined with continuously operating gravimetric systems, o� er a savings potential of 5 % or more in used material.

EASY TO USE.

Of importance for the success of a measuring and control system is not only the savings potential but also an easy opera-tion. WARP 8 is able to set a new standard here. The automatic centering by way of an XY cross table and the fact that no dimensioned components are required simplify enormously the process of setting the system into operation. Another strong point is the user-friendliness of the visualization software. All the line operator has to do is select a pipe recipe and start the measuring process.

RELIABLE DETECTION OF SAGGING.

On account of the 8 measuring points of WARP 8, the system is able to safely detect sagging at the critical points. Further, the operator receives measuring data on diameters, ovality and eccentricity across 4 axes.

HIGHLY PRECISE WALL THICKNESS AND DIAME-TER MEASUREMENT OF 8 MEASURING POINTS!

BENEFITS:

Comprehensive product information (wall thickness, diameters, eccentricity, ovality)

Absolute measurement

Automatic centering

Independent of pipe temperatures

Maintenance-free

Material savings of 5 % or more through s-min control or thin points control, improved centering process and a systematic start-up of the extrusion line

Documentation for submission to the customer

Proven control principles

Easy connection to extruder control

Easy to use, thus low training needs

MAJOR SAVINGS POSSIBLE.

WARP 8 sensor distribution + XY cross tableWARP 8 sensor distribution + XY cross table

Wall thickness measurement on 8 measuring points

Diameter measurement across 4 axes

Automatic calculation of the refractive index (mono-pipe)

S-min control (without gravimetry)

Alarm handling

Documentation and iTREND

When combined with gravimetry:

Thin point control

Mass throughput control

Weight per length control via haul-o� or extruder

Wall thickening

MEASUREMENT, CONTROL AND EVALUATION BY WARP 8:

WARP - 21“ Terminal

8 9

TypePipe dimension

[mm]Pipe dimension

[inch]

WARP 8 / 250 60 - 250 2.36 - 9.84

WARP 8 / 400 90 - 400 3.54 - 15.75

WARP 8 / 630 90 - 630 3.54 - 24.80

WARP 8 / 1200 250 - 1200 9.84 - 47.24

WARP 8 / 250

Page 6: WARP Terahertz systems - iNOEX€¦ · WARP Terahertz systems WARP 8 Version with 8 sensors: WARP 8 measures wall thickness sizes on 8 measuring spots in a highly accu-rate process

MEASURING CYCLES ROTATE ELECTRONICALLY AROUND THE MEASURED OBJECT AND CARRY OUT A 100 % INS-PECTION.

WARP 100 represents a technological quantum leap for pipe measurement. The system is able to comply with the need for higher quality demands in view of product safety, size accuracy, complete proof of quality and a reliable product traceability. WARP 100 inspects 100 % of a pipe wall thickness in both lengthwise and circumferential direction. All of this up to a line speed of 60 m/min (196.85 ft/min).

The core parts of WARP 100 are the intelligent WARP transceivers developed by iNOEX. These transceivers subsequently transmit and receive terahertz signals and evaluate the recorded data afterwards by way of algorithms.

Any automation system available on the market is not only assessed by its measuring quality but also by its comfortable operation, handling and reliability. Due to its indepen-dence of temperatures, the automatic centering via XY cross table and the easy operati-on of the visualization software, WARP 100 is able to meet these high demands entirely.

100 % WALL THICKNESS MEASU-REMENT FOR GAS AND PRESSURE PIPES!

WARP 100 Measuring principle

100 % wall thickness measu-

rement

BENEFITS:

Comprehensive product information (wall thickness, diameters, eccentricity, ovality)

100 % wall thickness measurement

Absolute measurement

Automatic centering

Independent of pipe temperatures

Maintenance-free

Material savings of 5 % or more through s-min. control or thin points control, improved centering process and a systematic start-up of the extrusion line

Optimum support for the operator

Traceability of the product

Documentation for submission to the customer

Proven control principles

Easy connection to extruder control

Easy to use, thus low training needs

100 % wall thickness measurement

Diameter measurement across 31 axes (WARP 100 / 1200)

Automatic calculation of the refractive index(mono-pipe)

S-min control (without gravimetry)

Alarm handling

Documentation and iTREND

When combined with gravimetry:

Thin points control

Mass throughput control

Weight per length control via haul-o� or extruder

Wall thickening

TypePipe dimension

[mm]Pipe dimension

[inch]

WARP 100 / 250 90 - 250 3.54 - 9.84

WARP 100 / 400 110 - 400 4.33 - 15.75

WARP 100 / 630 250 - 630 9.84 - 24.80

WARP 100 / 1200 400 - 1200 15.75 - 47.24 WARP - 21“ Terminal

MEASUREMENT, CONTROL AND EVALUATION BY WARP 100:

WARP 100 / 630

Pipe dimension

3.54 - 9.84

4.33 - 15.75

9.84 - 24.80

15.75 - 47.2415.75 - 47.2415.75 - 47.24WARP 100 / 630 100 / 630

10 11WARP 100 WARP 100

Page 7: WARP Terahertz systems - iNOEX€¦ · WARP Terahertz systems WARP 8 Version with 8 sensors: WARP 8 measures wall thickness sizes on 8 measuring spots in a highly accu-rate process

WARP - 21“ Terminal

WARP portable WARP Process visualization

THE SOLUTION FOR DIRECT MEASUREMENT WITHIN SECONDS!

WARP portable and display

wall thickness measurement

12 13

BENEFITS: Comprehensive product informati-

on (wall thickness)

Data logging including timestamp and measurement position on pipe circumference

Data transmission via WLAN or USB to Smartphone, Tablet or PC

Measurement in just seconds

Direct measurement independent of temperatures

Exchangeable centering aids

Low maintenance

Robust, splash-proof housing (IP54)

Easy to use

VISUALIZATION!

INDEPENDENCE OF PIPE TEMPERATURES AND RELIABLE PERFORMANCE.

WARP portable is a mobile terahertz based hand-held system specifi cally desi-gned for medium and large-sized extruded pipes. The battery-operated hand-held device o� ers a fast and easy wall thickness point measurement of plastic pipes having a wall thickness of 6 mm (0.236“) or more, measuring precision is 50 µm (0.0019“).

The modern economic design of WARP portable o� ers maximum user conve-nience. Measuring results are displayed on an LCD display by pushing only one button. WARP portable and the respective centering aid just need to be placed onto the pipe and the button must be pressed.

WARP portable which is low-maintenance is supplied with a data logger inclu-ding timestamp and the measuring position on the pipe circumference, data transfer via WLAN or USB directly to a Smartphone, Tablet or PC. Further advan-tages are the splash-proof housing (IP 54) and the long battery life of approx. 10 hours.

WARP portable - Scope of delivery

SCOPE OF DELIVERY: Two exchangeable centering aids, one for large diameters, the other for

medium-sized pipes

Delivered in a robust plastic case

Long battery life of approx. 10 hours

EASY INTEGRATION.

The future-oriented and platform-independent concept al-lows visualization as a website by way of an easy integration via browser. As such, the iNOEX user interface is displayable on all web-enabled devices. The multi-touch surface allows an intuitive navigation through gestures (zooming, wiping).

Operation is carried out by way of installed widgets. On the interface, the user is free to confi gure, add or remove the widget‘s size or information value, just as he wishes. As such, the user has constant access to his most important applications (favorites).

FAST CUSTOMER SUPPORT VIA

TEAMVIEWER: Direct global support via remote control

Easy confi guration, no VPN gateway

Adherence to the highest safety standards

Page 8: WARP Terahertz systems - iNOEX€¦ · WARP Terahertz systems WARP 8 Version with 8 sensors: WARP 8 measures wall thickness sizes on 8 measuring spots in a highly accu-rate process

LOGGING, ANALYSIS AND EVALUATI-ON OF YOUR PRODUCTION DATA.

The iNOEX data manager (IDM) features a central data log-ger for the collection of all process and quality data of all standard iNOEX systems along the extrusion line.

The software is installed on a virtual machine on an existing server in your network which means that no additional hardware is required. The analysis and evaluation of your data is carried out by the integrated iTREND function. Data can be downloaded for further processing, e.g. as CSV fi le.

BENEFITS: Access to all relevant product data

Visualization and data evaluation by iTREND

Older systems can be addressed by an additional gateway

Supports quality assurance

Easy access via web browser

iTREND.

iTREND visualizes your production and process values in the form of diagrams. Display of process data and time periods can be individually adapted by the user. Besides pre-defi ned diagrams the user-friendly software o� ers cus-tomized presentations of process values.

Storage as CSV fi les permits the easy export of protocols for documentation purposes for the customer. Operation of iTREND is intuitive and it is done via web browser on PC, notebook or tablet in your network.

IDM - THE INOEX DATA MANAGER!

IDM, iTREND Payback14 15

WARP 100 Ø 630 mm (PE-PIPE; WARP with 19 sensors)

Output Production time Savings Material costs Savings p.a.

1200 kg/h 16 hrs/day x 350 days/year 2.0 % (WARP) 1.20 €/kg 161,280 €

1200 kg/h 16 hrs/day x 350 days/year 3.0 % (Gravimetry) 1.20 €/kg 241,920 €

5.0 % total 403,200 €

WARP portable (Ø 1200 mm PE; weight per length 54,6 kg/m; recycling costs 0.46 €/kg)

Produced pipe length up to sella-

ble pipeScrap

Recycling costs per line start

Costs for energy,

personnel, etc.

Costs per line start

without WARP portable 2 x 9 = 18 m 982.8 kg 452 € 414 € 866 €

with WARP portable 2 m 109.2 kg 50.2 € 23 € 73.2 €

Savings through WARP portable 792.80 € per line start

ENORMOUS SAVINGS POTENTIAL!

WARP systems o� er not only an excellent price-performance ratio but also very short pay-back periods. Depending on mass throughput rates and production time, payback may even be within a few months.

WARP 8 Ø 250 mm (PE-PIPE; WARP with 8 sensors)

Output Production time Savings Material costs Savings p.a.

500 kg/h 16 hrs/day x 350 days/year 2.0 % (WARP) 1.20 €/kg 67,200 €

500 kg/h 16 hrs/day x 350 days/year 3.0 % (Gravimetry) 1.20 €/kg 100,800 €

5.0 % total 168,000 €

iTREND - Trend chart example I

iTREND - Trend chart example II

Page 9: WARP Terahertz systems - iNOEX€¦ · WARP Terahertz systems WARP 8 Version with 8 sensors: WARP 8 measures wall thickness sizes on 8 measuring spots in a highly accu-rate process

GERMANYiNOEX GmbHPhone.: +49 5422-60507-0Fax: +49 5422-60507-101

UNITED KINGDOMiNOEX o� ce UKPhone: +44 1782-52-3621Fax: +44 1782-52-3621

TURKEYiNOEX o� ce TurkeyPhone: +90 544-434-5938Fax: +90 216-365-0837

CHINAiNOEX Ltd.Phone: +86-10 8526-1153Fax: +86-10 8526-1328

USAiNOEX LLCPhone: +1-717 672-0870Fax: +1-717 672-0872

[email protected]

© iNOEX GmbH – All rights reserved. Reproduction in total or in parts without explicit written approval by the copyright owner is prohibited. iNOEX GmbH reserves the right to change a product or to terminate its production at any time without prior announcement and without any obligation. Errors or technical changes excepted. Revised March 2018.