ODAC® / USYS
In-line & Off-line Dimensional & Quality Control
ODAC® – Laser Diameter & Dimension Measuring Gauges
USYS – Universal Data Acquisition, Processing & Display Systems
ODAC® Laser scanners
ODAC® is the registered trademark for laser diameter and
dimensional measuring gauges from ZUMBACH Electronics,
one of the leading manufacturers in this domain. Over 70'000
ODAC® scanners or systems are operating worldwide for inline measurement of diameter, ovality and other dimensions
in industrial processes.
ZUMBACH, headquartered in Switzerland, was founded
1957 and is a pioneer in in-line measurement for many
quality parameters. Today, the ZUMBACH group serves the
world market with 13 subsidiary companies and with over
40 agencies.
240
(9.45)
240
(9.45)
50
(1.97)
50
(1.97)
1-axis
Measuring field
Min. product diameter
Scanning frequency
Scan speed m/s, (ft./s)
Repeatability*
µm
(in.)
Linearity
µm (in.)
ODAC 2J
2 mm
(.079 in.)
0.012 mm(.0005 in.)
240/s
18.8
(62)
± 0.15
(± .000006)
± 0.3 (± .000012)
ODAC 16J
16 mm (.64 in.)
0.05 mm (.002 in.)
240 or 480/s
24 or 48(79 or 158)
± 0.15
(± .000006)
± 0.5 (± .00002)
± 0.1 ‰
Modular design
240 (9.45)
18 (.7)
Dual axis
Measur. field (mm/in.)
Min. product diameter
Scanning frequency
Scan speed
m/s
(ft./s)
Repeatability* µm (in.)
Linearity
µm (in.)
Triple axis
Measur. field (mm/in.)
Min. product diameter
Scanning frequency
Scan speed m/s, (ft./s)
Repeatability* µm (in.)
Linearity
µm (in.)
ODAC 15XY-JM
3 x 3
(.12 x .12)
0.015 mm (.0006 in.)
2 x 200/s
26.7
(87.6)
± 0.1 (± .000004)
± 0.3 (± .000012)
730 - 1480
(28.74 - 58.27)
120 - 800
(4.7 - 31.5)
200 - 800
(7.8 - 31.5)
250 - 1000
(9.84 - 39.37)
350 - 1000
(13.77 - 39.37)
1320 - 2820
(51.97 - 111.02)
1750 - 2950
(68.89 - 116.14)
500 - 2100
(19.69 - 78.74)
800 - 2000
(31.49 - 78.74)
ODAC 230J 1)
230 mm
(9.45 in.)
0.75 mm
(.04 in.)
1000/s
473
(1988)
± 0.6
(± .000023)
± 5
(± .0002)
ODAC 310J 1)
310 mm
(12.2 in.)
1 mm
(.04 in.)
1000/s
606
(1988)
±2
(± .00008)
± 25
(± .0001)
ODAC 550J 1)
550 mm
(21.6 in.)
1.5 mm
(.06 in.)
500 or 1000/s
1056
(3464)
±3
(± .00012)
± 50
(± .002)
•
•
•
•
•
•
260 (10.24)
18 (.7)
320 (12.6)
420 (16.54)
630 (24.80)
30 (1.18)
51.75 (2.04)
110 (4.33)
ODAC 63TRIO 1)
3 x 64
(3 x 2.52)
0.25
(.01)
3 x 600/s
173
(567.5)
± 0.3 (± .000012)
± 2
(± .00008)
± 0.1 ‰
Available versions with in-built processor
(besides the proven "J" version):
– RS (-232 / -422 / -485)
– DP (PROFIBUS DP)
– EN (ETHERNET)
– CAN-Bus (on request)
1000 - 1650
(39.37 - 64.96)
ODAC 160J 1)
160 mm
(6.3 in.)
0.5 mm
(.02 in.)
1000/s
328
(1076)
± 0.4
(± .000016)
± 3
(± .00012)
ODAC 18XY-J 1)
18 x 18
(.71x .71)
0.08 mm (.003 in.)
2 x 1200/s
67.8 (222.4)
± 0.05 (± .000002)
± 0.5
(± .00002)
± 0.1 ‰
All dimensions in mm and (inches) resp. (µm) 1µm = 0.001mm
2
560 - 1160
(22 - 45.7)
ODAC 100J 1)
100 mm
(3.93 in.)
0.25 mm
(.01 in.)
1000/s
219
(718)
± 0.5
(± .000019)
± 2
(± .00008)
18 (.7)
1)
Interfaces: RS-232/-422/-485, PROFIBUS DP,
ETHERNET TCP/IP
Scan rate per axis: Up to 1200/s (optional 2400/s)
Measuring rate
With CSS technique up to 1200 values
per axis: per second for further processing
For service and local display: depending model
ODAC 60J
60 mm
(2.36 in.)
0.2 mm
(.008 in.)
1000/s
150.8
(495)
± 0.3
(± .000012)
± 2
(± .00008)
240 (9.45)
* For ± 3 Sigma and 1 s averaging time
Many ODAC® models are available with in-built intelligence
and high performance processors. An integrated lump
detector function is also available in several models.
380 - 1060
(15 - 41.7)
ODAC 15XY-J
16 x 16
(.64 x .64)
0.04 mm (.0016 in.)
2 x 200 or 2 x 400/s
26.7 or 53.4
(87.6 or 175.8)
± 0.1 (± .000004)
± 0.5
(± .00002)
± 0.1 ‰
ODAC 33TRIO 1)
3 x 34
(3 x 1.34)
0.15
(.006)
3 x 600/s
98.3 (322.5)
± 0.1 (± .000004)
±1
(± .00004)
± 0.08 ‰
Intelligent and Fast Scanners
ODAC 113TRIO 1)
3 x 110
(3 x 4.33)
0.5
(.02)
3 x 600/s
295.5
(969.5)
± 0.5 (± .000018)
± 5
(± .0002)
± 0.05 ‰
310 (12.2)
390 (15.35)
530 (20.87)
800 (31.49)
60 (2.36)
102 (4.02)
165 (6.49)
ODAC 110XY-J 1)
110 x 110(4.33 x 4.33)
0.5 mm
(.02 in.)
2 x 1200/s
354.6
(1163.4)
± 0.4 (± .000016)
± 5
(± .0002)
± 0.05 ‰
ODAC 160XY
160 x 160 (6.3 x 6.3)
1.5 mm
(.06 in.)
2 x 500/s
328
25 (.98)
ODAC 34XY-J 1)
34 x 34 (1.34 x 1.34)
0.15 mm (.006 in.)
2 x 1200/s
117.9
(386.8)
± 0.06 (± .0000025)
± 1
(± .00004)
± 0.08 ‰
ODAC 64XY-J 1)
64 x 64 (2.52 x 2.52)
0.25 mm
(.01 in.)
2 x 1200/s
207.5
(680.8)
± 0.2 (± .000008)
± 2
(± .00008)
± 0.1 ‰
± 0.6 µm (± .000023)
± 3
(± .00012)
± 0.1 ‰
Innovation
New and more difficult functions call for innovative solutions like:
•ODAC® F
For high-precision, non-contact laser diameter measurement
with extremely high scan rates and with integrated fault
detection function. Up to 4500 measurements/s can be
processed from 3-axis scanner. A special laser beam geometry
enables the detection and process of very small defaults or
diameter variations.
•CSS: Calibrated Single Scan Measurement
Up to 1200 measured values/s at highest accuracy.
– New technique, optically and electronically
– Selective measurement at high speeds
•HLF Technology (High accuracy Large Field)
At the heart of the development are special optic components
of very high precision used for collimation and focusing. This
high-tech system generates an absolutely parallel (telecentric)
measuring field for very large measuring ranges (up to
550 mm / 21.5 in.) without dead zone.
Outstanding Advantages
ODAC® Laser Scanners
USYS Processors
• High resolution and accuracy
• High measuring rate, up to 2400 / s
• FFT / SRL analysis with higher bandwidths
• Integrated fault detection function
• Permanent calibration
• Robust and longevity
• Insensitive to dirt
• Optically immune
• No safety problems
• For each application and each budget the optimal model
• Extremely fast and powerful thanks to
ZUMBACH hardware and real-time software
• Industrial, easy to operate
• Rugged and stable evaluation and processing system
• Programmes on flash disc (no hard disc)
• Process specific configuration and software packages
• Flexible for extension
Measuring principle and technology
A focused laser beam at a high rate is scanning the object.
The time of obscuration is captured with a resolution of
0.00001 mm (.0000004 in.) as a dimension (shadow) and
then further processed.
Material, colour, temperature etc. of the object has no
influence on the measurement.
Depending on the model, high absolute accuracies are
achieved (0.001... 0.02 mm / .00004 ... .0008 in.). Thanks to
the new CSS technique (Calibrated Single Scan), up to 1200
values /s or more can be processed and made available.
Measuring Modes
In combination with appropriate
signal processing and / or auxiliary
mechanical devices, practically any
measuring mode can be realized.
Typical measuring modes
Multiple objects
Position
Penetration
Large diameters
Gap
Length / Width
Thickness
(with pivoting support)
Absolutely parallel
Receiver
Emitter
Measuring field
Measured dimension
(shadow)
Laser scan, with high
rates, typically 1200/s
Technology
Latest technology in laser, optics and
electronics are used. ODAC® laser
heads are made with Swiss precision
and are renown for their accuracy,
reliability, and extremely long lifetime;
and this at ever higher scan speeds
and rates.
Harsh Environments
Diameter
Laser beam
Special solutions are available for
processes with harsh environments,
such as:
–Measurement through water
–Measurement in CV tubes
–Measurement in hot rolling
environment
–Extremely hot processes,
up to 2100° C (3632° F)
Output signal
(Video)
Video
d
Counting clock
A Complete Line of
USYS Processors
A complete line of devices for the data
processing, display, statistics, process
control and networking is available for
any specification and budget. All
USYS processors are industrial, stable,
easy to operate and extendable. They
can process up to 6 ODAC® heads
plus other sensors, speed and event
inputs.
Fast Real Time
The unique CP XX pre-processors in
ODAC® sensors or USYS processors
enable, at the same time, fast, accurate
and consistent readings thanks to
sophisticated filter and computation
algorithms.
Up to 2400 measurements/s can be
p r o ce s s e d , d e p e n d i n g o n t h e
measuring head.
The SIGMA EXPERT Controller
Most USYS processors are available
with this self-adapting controller type,
which guarantees tighter product
tolerances and considerable material
savings.
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Data acquisition, processing and display systems
0.1 µm
USYS 20
USYS 200
USYS 2100
•
4.2" •
monochrome
•
6.4" •
LCD colour
•
•
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•
•
•
•
0.1µm
•
•
•
0.1µm
•
•
•
•
•
•
•
0.01µm
8.4" •
LCD colour
•
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0.01µm
•
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1•
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4
•
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3•
•
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2•
2•
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3•
•
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2 •; 4
2 •; 4
•
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1•
1•
2•
2•
1•
1•
1•
2•
1•
1•
2•
2•
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Operation / Peripherals
•
WIREMASTER
•
Measurement Data Processing
AT 4
•
Nomenclature:
• = Standard
= Option
= Only 1 feature at once
USYS IPC 1
USYS IPC 2
USYS IPC 8 Features
LED Display
Separate 19" Separate 19" Separate 19" Screen
touch screen • touch screen • touch screen •
•
•
•
System editor
•
•
•
Terminal for SPC charts
•
•
•
Remote display
•
•
•
Input external start/stop
•
•
•
Input external pause
•
•
•
Input external keyboard
•
•
•
Input line speed detection
•
•
•
Start/Stop
•
•
•
Pause
0.01µm
0.01µm
0.01µm
Resolution
Wall thickness measurement
•
•
•
with 2 ODAC heads
Wall thickness measurement
•
with ultrasonics
•
•
•
Capacitance measurement
•
•
•
Measurement gap width
•
•
•
Penetration depth
•
•
•
Serial up/download
•
•
•
Ethernet (TCP/IP protocol)
•
•
•
Web Server
2•
3•
3•
USB
•
•
•
RS-232 printer
•
•
•
Parallel printer
2 •; 4
2 •; 4
2 •; up to 10 Simultaneous serial outputs
2 •; 4
Max. 12
Max. 20
Analog outputs
•
•
•
Product library
•
•
•
Hot/cold measurement
Number of connectable
2•
3•
6•
measuring heads
Number of event inputs
2•
2•
4•
for sparks, lump etc.
•
•
•
Alarm +
•
•
•
Alarm –
•
•
•
General alarm
Diagnostics
and Alarms
•
•
•
Pre-Alarm
•
•
•
Self diagnosis
•
•
•
Statistic alarm
•
•
•
Hot/cold controller
•
•
•
Static controller (SRD)
Controller
•
•
•
SIGMA EXPERT
•
•
•
Cpk pilot
•
•
•
Simple statistics
•
•
•
SPC with control charts
•
•
•
Package report
Statistics
•
•
•
Data Log
•
•
•
Job Report
convincing Solutions
The list of all possible applications and specific benefits of the various ZUMBACH systems is practically endless. The following
represents some of the most typical applications:
Cable industry
•Diameter & ovality
measurement / control
•Average wall thickness
•Width / Height
– Bare wire
– Cores
– Bundles
– Fillers
– Jackets
– Sectors
– Flat cables
– MV and HV cables
– Automotive cables
– Data cables
– Optical fibres
– Coatings
Wire Drawing
•Diameter & ovality
measurement / control
•Turbo Air Guard
for dry lubrication
– Wet lubrication
– Dry lubrication
– Copper wire
– Steel wire
– Steel cord
– Special wires
– Profile wires
Medical, Food,
Cosmetic, Packaging
Plastic & rubber
extrusion
•Diameter & Ovality
•Multi strand
– Hoses
– Rods
– Tubes
– Blown film diameter
– Sausage casings
•Diameter & ovality
measurement / control
•Width / Height
•Multi strand
– Tubing
– Tubes
– Hoses
– Large tubes / pipes
– Profiles
– Ribbons
– Multi strands
– Blown Film Diameter
Measurement of Insulations or Jackets on Cables
For the extrusion of cores or jackets the USYS IPC WALLMASTER system offers many possibilities thanks to its flexibility and
easy handling. All parameters, thickness, eccentricity, diameter and ovality, can be controlled.
• For core insulation
• For jackets, also when loose
or non-round
• For co-extrusion
• Automatic calibration with
DIACAL system
• Hot / cold compensation
Remote display
Control
USYS IPC 2 WALLMASTER
Printer
UMAC® CI
UMAC®
ODAC®
ODAC®
KW
Steel & Metal Industry
•STEELMASTER SMR, SMO or SMS systems •1 to 6 measuring axes
(ODAC® measuring heads)
– Hot rolled long products
– Wire rod, Bar
– Profiles
– Tubes / seamless pipe
– Cold rolled and drawn products
•EPM – "Enhanced Profile
STEELMASTER measuring unit
Measurement" (patent pending)
The Measuring Method for
Special Product Geometries
Typical configuration of a combined Bar / Rod mill with
3 STEELMASTER measuring units and 1 common STEELMASTER
processing and display unit.
STEELMASTER
processor
Intermediate
STEELMASTER
measuring unit
3-roll block
STEELMASTER measuring units
Scanning a multitude of shadow edges around the entire periphery captures the product shape. This is achieved with several
ODAC® measuring heads, scanning synchronously with high accuracy. Also polygonal faults or other irregular geometries are
accurately detected.
5
ODAC® / STEELMASTER – Systems for the Steel and Metal industry
Hot Processes
For heavy operating conditions in the area of steel and
metal industry, in particular for hot rolling, ZUMBACH
offers the special STEELMASTER program.
1 up to 6 ODAC® scanners form the heart of the measuring
units SMS (static), SMO (oscillating) or SMR (rotating).
The STEELMASTER electronics and software process the
measuring data for display, process monitoring, statistics
and for the data exchange with the customer's network.
Cold Processes
For cold processes, including cold rolling, drawing,
peeling, grinding and for quality control (NDT) and sorting,
ODAC® scanners with respective protection and USYS
or STEELMASTER processors are used, depending on the
case.
► Ask for special literature for above applications.
CommuniCation and networking
Today, the ability of sensors or processors to communicate with other computers or networks is essential. ZUMBACH offers
a variety of ODAC versions, interface units and USYS software to satisfy almost any need and concept.
ODAC® Manager
User-friendly software kit
for easy configuration,
calibration and verification
using a PC. Versions for
serial or ETHERNET
communication.
–Minimises set-up time
–Easy access
–Graphic / numeric
visualisation at a glance
–Easy, safe to retrieve
configuration to/ from
the PC
USYS Data Log
The USYS Data Log is a
WINDOWSTM based software
for easy data collection from
one or several ZUMBACH
processors and for saving
the data in text or ExcelTM
files.
USYS Data Log talks to
the ZUMBACH processors
via a serial RS-232 port
or an ETHERNET TCP/IP
connection.
TM
USYS Web Server
With this new option an
USYS processor with an IP
address can be addressed
over a local area network
(L AN, Intranet) via an
ETHERNET PCB, using a
b r o w s e r l i ke I n t e r n e t
Explorer or other.
USYS Report Manager
T he US Y S s y s t e m c an
store in a local or remote
disc the detailed statistics
calculated for the Piece,
Lot and SPC periods. In this
way it is possible to recover
and visualize the data
of previous productions
and reproduce the quality
control printed reports.
WINDOWS and Excel are trademarks
of Microsoft Corporation
• All technical data are subject to change without notice.
Worldwide customer service and sales offices
Zumbach Electronic AG, SWITZERLAND (H.Q.), [email protected]
Zumbach Electrónica Argentina S.R.L., Argentina, [email protected]
Zumbach Electronic S.A., Belgium, [email protected]
Zumbach do Brasil Ltda, Brazil, [email protected]
Zumbach Electronic Co. Ltd., China P.R., [email protected]
Zumbach Bureau France, France, [email protected]
Zumbach Electronic GmbH, Germany, [email protected]
6
ZUMB.001.5002.EN FEB.2014
Zumbach Electronic India Pvt. Ltd., INDIA, [email protected]
Zumbach Electronic Srl, Italy, [email protected]
Zumbach Electrónica S.L., Spain, [email protected]
Zumbach Electronics Far East, Taiwan, [email protected]
Zumbach Electronics Ltd., UK, [email protected]
Zumbach Electronics Corp., USA, [email protected]
www.zumbach.com