Measuring and inspection systems for rubber and tires

Measuring and inspection systems for rubber and tires

The rubber processing industry, as well as the tire production process is supported by Micro-Epsilon with a range of systems for inspection, monitoring and control of miscellaneous processes.

Tire width inspection

The dimensionCONTROL TWI 7303.I tire width inspection system is designed for profile width measurement in extrusion lines. This measuring system is based on camera vision technology involving two cameras inside one measurement box. These cameras are angle mounted to each other and operate according to stereo vision technology which enables high precision measurements in the whole calibration range.

Advantages:

  • Precise measurements in harsh environmental conditions (e.g. vibrations, unpredictable material movements on conveyor in material flow direction, in vertical directions or even combined)
  • Simultaneous measurement of two produced profiles
  • Automatic detection, measurement and profile evaluation
  • Visualization software offers database containing the measured profiles, recipes, tools for static processing and for export of different output formats

Material parameters: Tire width from 350mm to 550mm

Profile measurement of treads

The dimensionCONTROL TMWI 8302.LC system is suitable for the inline weight inspection of continuous running rubber profiles (tread pattern or sidewalls) for passenger and truck tires. Based on the force measurement principle, the inspection system uses two load cells which measure the deflection of the measurement conveyor. These sensor elements are attached to a massive construction, which ensures a long-term mechanical stability of the system. The measurement conveyor uses precise and balanced aluminum rollers with special surface treatment. This ensures a low deadweight, avoids influence of unbalance and eliminates material sticking. Data obtained from the load cells are processed in the implemented PLC cards which determine the measured weight mathematically.The software included offers a variety of measurement data processing, definition of design profiles, statistical analysis of measured profiles and diagnostic tools. Advantages:
  • Ideal for precise inline weight inspection of running tread profiles for passenger and truck tires
  • Adjustable extrusion head/controllable extruder
  • Automatic profile sorting and remote access
  • Ideal for harsh environments prevailing in the preparation area due to its robust design
Technical parameters:
  • Measuring range: weight up to 10 kg/m
  • Weight accuracy < ±1 g (static); < ±5 g (dynamic)
  • Length of the weighing conveyor: 500 m

On-roll profile thickness measuremen

The thicknessCONTROL TCP 8303.ET measuring system accepts the challenge of profile thickness measurements in calender rolls where it solves complex tasks in harsh environments while providing the data required to optimize the production process. Similar to the thicknessCONTROL TCP 7303.ET, the measuring principle of the system is based on the combination of a laser triangulation sensor and an eddy current sensor.

Advantages:

  • Continuous monitoring and readjustment of the measuring head position using multiple sensors
  • Complete calender monitoring: 2x TCP8303.ET and 1x thicknessCONTROL TCP 8301.CT or TCP 8301.CLLT
  • Software package allows for 3 measuring systems to be easily operated simultaneously

Material parameters: Measuring widths from 1400mm to 2200mm

Tire geometry inspection

Monitoring tire geometry i.e. the measurement of radial or lateral unbalance as well as side wall detection for bulges, constrictions, dents etc., is one of the most important inspections at the end of the production process. The TGI 8302.LLT system can be easily integrated while offering precise measuring results.

Benefits:

  • Suitable for all common TU machines and therefore ideal for retrofit
  • Optical measuring principle
  • Total surface scan
  • Reduced pseudo-error rate
  • Robust, low-vibration construction

Material parameters:

  • Tire width from 100mm to 460mm
Special features:
  • Resolution: 640 points per profile, 2,000 profile/s
  • Reproducibility 40µm (3-sigma)
  • Cycle time: 1s/60 R/min

The system TGI 8302.LLT uses three profile sensors which reliable detect bulges and constrictions as well as radial and axial unbalance. The sensors are integrated in a robust mechanics and applied in such a way that the total surface of the tire can be detected within one rotation. Thereby, the tester visualizes the tire surface, hides the tire lettering, enables filtering of data, performs a vibration check, inspects the tire size and classifies the degree of a defect.

Profile measurement of inner liner material

During the production of inner liner, the thickness profile of inner liner material is measured immediately after the calender using systems of the thicknessCONTROL TIP series. Accurate precision of the non-contact optical system ensures high quality and security of the product produced. Sensors belonging to the thicknessCONTROL RTP series can also be applied for this application.

Benefits:

  • Permanent high product quality while reducing raw material use
  • Fast controlling during warm up or product change due to adaptive traversing speed and high-dynamically measurement
  • No consequential costs due to isotopes or X-rays
  • Wear-free measurements instead of half time of radiometric tests
  • Highest temperature stability due to in-situ calibration and compensation elements
  • Customer-specific adjustable interface

Material parameters:

  • Material width from 200mm to 3,800mm
  • Material feed up to 25m/min
  • Permitted material surface temperature max: 100°C

Being equipped with optical sensors, systems of the TIP family are designed as O- and C-frames. Temperature fluctuations of the measuring mechanics are additionally detected using distance and temperature sensors and are therefore algorithmically compensated. Systems of the RTP series can be applied as low-cost solutions.

Special features:
  • Linearity ±5µm
  • Measuring gap 15mm
  • Dimensional thickness measurement, independent from material components

The system TIP 8301.EO operates according to a combination principle consisting of a thru-beam sensor, an eddy current sensor and a measuring roller. The eddy current sensor and the thru-beam sensor are applied on an innovative measuring clamp. Since the sensor measures the distance from the clamp to the roller, the lower side of the material is detected. Since the sensor performance is specially aligned with the measuring task a huge measuring gap is possible while offering highest precision. The thru-beam sensor detects the upper side of the material. The thickness of the target is the difference between the two signals. The measuring clamp is equipped with a pneumatically cleaning mechanism and therefore ideal for the application in harsh environment.

Special features:
  • Linearity ±5µm
  • Measuring gap 18mm
  • Dimensional thickness measurement, independent from material components

The TIP 8301.CT is based on the laser triangulation sensors and therefore ensures the measurement being independently from material constants. The system is designed as O-frame, both sensors detect the thickness according to the differential method. In order to ensure highest precision, the laser beams of the sensors are accurately adjusted during the production process using optoelectronic tools which have been specially developed. The system is ideal for monitoring high-dynamically processes due to its high measuring rate. The O-frame mechanics of the system dispose of a compensation frame which does not vary with temperature and which is used in order to avoid temperature fluctuations of the measuring frame using further sensors.

Special features:
  • Linearity ±10µm
  • Measuring gap 20mm
  • Dimensional thickness measurement, independent from material components

The TIP 8301.ET is based on the laser triangulation sensors and therefore ensures the measurement being independently from material constants. The system is designed as O-frame, both sensors detect the thickness according to the differential method. In order to ensure highest precision, the laser beams of the sensors are accurately adjusted during the production process using optoelectronic tools which have been specially developed. The system is ideal for monitoring high-dynamically processes due to its high measuring rate. The triangulation sensor applied on the upper side is combined with an eddy current sensor which monitors the distance of the two optical measuring sensors while allowing a software-technical compensation of temperature-induced changes of the measuring gap. Additionally, the compensation sensor is applied according to a special alignment with the measuring task in order to ensure both, a huge measuring gap and highest precision.

Special features:
  • Linearity from ±5µm
  • Measuring gap 20mm
  • Immersion depth from 50° to 1,000mm
  • Special sizes on request
  • Measuring rate to 20kHz

The RTP 8302.T is based on the laser triangulation sensors and therefore ensures the measurement being independently from material constants. In order to ensure highest precision, the laser beams of the sensors are accurately adjusted during the production process using optoelectronic tools which have been specially developed. The system is ideal for monitoring high-dynamically processes due to its high measuring rate. The C-frame mechanics of the system disposes of an automated in-situ calibration in order to avoid interferences caused by temperature.

Special features:
  • Linearity ±10µm, 40mm measuring range
  • Gap width 300mm
  • Immersion depth from 50° to 1,000mm
  • Special sizes on request
  • Measuring rate to 2kHz

The RTP 8302.LLT is based on the laser line triangulation sensors and therefore ensures the measurement being independently from surface characteristics of the target material. Combined to point sensors, the system offers more precision in the case of gap width. The C-frame mechanics of the system disposes of an automated in-situ calibration in order to avoid interferences caused by temperature.

Profile measurement of inner liner material

The profilometer of the thicknessCONTROL.TTP series accurately measures the thickness profile of tire tread or side walls during the extrusion process and enable therefore an efficient control during production as well as a fully recorded quality control.

Benefits:

  • Optimizing the material use and quality
  • Fast controlling during warm up or product change due to adaptive traversing speed and high-dynamically measurement
  • No consequential costs due to isotopes or X-rays
  • Wear-free measurements instead of half time of radiometric tests
  • Easy integration to already existing lines
  • Customer-specific adjustable interface

Material parameters:

  • Material width to 2,000mm
  • Strip width from 5mm to 550mm
  • Up to 6 single strips
  • Material feed up to 60m/min

The systems of the TTP family are equipped with optical sensors and have an application specific operators´ frontend which provides all necessary data regarding the organization of the extrusion process of running surfaces and side walls. Systems of the RTP series can be applied as low-cost solutions.

Special features:
  • Accuracy thickness 60µm
  • Accuracy width 0.3mm
  • 40 profiles per second

The TCP 8301.I is based on the light intersection method. On each material side a line is projected crosswise on the measuring object via a laser light source. The profile is detected by a camera. The geometrical data are calculated from the distance of the cameras and the signals from the lower and upper material side. A long-term and temperature stability is achieved by an automated in-situ calibration.

Special features:
  • Accuracy thickness ±10µm
  • Accuracy width 0.2mm
  • Measuring rate to 20kHz

The TCP 8301.ET is based on laser triangulation sensors and therefore ensures the measurement being independently from material constants. The system is designed as O-frame, both sensors detect the thickness according to the differential method. In order to ensure highest precision, the laser beams of the sensors are accurately adjusted during the production process using optoelectronic tools which have been specially developed. The system is ideal for monitoring high-dynamically processes due to its high measuring rate. The triangulation sensor applied on the upper side is combined with an eddy current sensor which monitors the distance of the two optical measuring sensors while allowing a software-technical compensation of temperature-induced changes of the measuring gap. Additionally, the compensation sensor is applied according to a special alignment with the measuring task in order to ensure both, a huge measuring gap and highest precision. The TCP 8301.ET is similarly to the TIP8301.ET regarding its functionality. However, they differ concerning the application- or process specific user interface and the corresponding analyzes software.

Special features:
  • Linearity thickness ±5µm
  • Accuracy width 0.3mm
  • Measuring rate to 20kHz

The TCP 8301.CT is based on laser triangulation sensors and therefore ensures the measurement being independently from material constants. The system is designed as O-frame, both sensors detect the thickness according to the differential method. In order to ensure highest precision, the laser beams of the sensors are accurately adjusted during the production process using optoelectronic tools which have been specially developed. The system is ideal for monitoring high-dynamically processes due to its high measuring rate. The O-frame mechanics of the system dispose of a compensation frame which does not vary with temperature and which is used in order to avoid temperature fluctuations of the measuring frame using further sensors. The TCP 8301.CT is similarly to the TIP8301.CT regarding its functionality. However, they differ concerning the application- or process specific user interface and the corresponding analyzes software.

Special features:
  • Linearity from ±5µm
  • Measuring gap 20mm
  • Immersion depth from 50° to 1,000mm
  • Special sizes on request
  • Measuring rate to 20kHz

The RTP 8302.T is based on the laser triangulation sensors and therefore ensures the measurement being independently from material constants. In order to ensure highest precision, the laser beams of the sensors are accurately adjusted during the production process using optoelectronic tools which have been specially developed. The system is ideal for monitoring high-dynamically processes due to its high measuring rate. The C-frame mechanics of the system disposes of an automated in-situ calibration in order to avoid interferences caused by temperature.

Special features:
  • Linearity ±10µm, 40mm measuring range
  • Gap width 300mm
  • Immersion depth from 50° to 1,000mm
  • Special sizes on request
  • Measuring rate to 2kHz

The RTP 8302.LLT is based on the laser line triangulation sensors and therefore ensures the measurement being independently from surface characteristics of the target material. Combined to point sensors, the system offers more precision in the case of gap width. The C-frame mechanics of the system disposes of an automated in-situ calibration in order to avoid interferences caused by temperature.

Offline profile thickness measurement

The profilometer thicknessCONTROL TTP 8302.T is applied for sampling regarding the extrusion process of treads, side wall and inner liner material. The system offers measuring results in high precision and allows therefore an efficient production as well as a fully recorded quality control.

Benefits:

  • Manual measurements which are prone to error are replaced and quality control is optimized
  • More efficient, manual setting of the extrusion nozzle reduces consumption of material
  • No consequential costs due to isotopes or X-rays
  • Wear-free measurements instead of half time of radiometric tests
  • Statistical documentation and permanent improvement of the production process
  • Economical solution to control various lines by one system

Material parameters:

  • Material width to 600mm
  • Material thickness to 50mm

The system TTP 8302.T is equipped with optical sensors and has an application specific operators’ frontend which provides all necessary data regarding the organization of the extrusion process of treads and side walls.

Special features:
  • Accuracy thickness ±50µm
  • Accuracy width ±0.5mm

The TCP 8302.T is based on laser triangulation sensors and therefore ensures the measurement being independently from material constants. In order to ensure highest precision, the laser beams of the sensors are accurately adjusted during the production process using optoelectronic tools which have been specially developed. Offering an easy operation, the system provides an in-situ calibration unit and ensures high precision.

Length measurement of tread strips

For tire production, tread strips are cut from the extruded strip material. The system TLS 8303.I is applied in the extrusion line to measure the length of the strips immediately after the cutting machine in order to ensure a secure production process in high quality.

Benefits:

  • Optimizing the material use and quality
  • Geometrically independent comparison of cutting edges
  • Easy integration to already existing lines
  • Customer-specific adjustable interface

Material parameters:

  • Strips lengths from 1,500mm to 2,500mm
  • Feed rate to 2m/s
Special features:
  • Resolution 0.125mm
  • Cycle time: 3 strips per second
  • Strip length offset ±50mm

At the optical testing desk TLS 8303.I, rubber strips for tire production are inspected for their profile and length characteristics. Two cameras record the cutting edges of the strips. Deviations from the nominal cutting edge are detected by an intelligent composition proceedings. The cutting edges are compared to each other in order to evaluate the strip lengths. Therefore, the pictures are revalued using a stabilizer filter and different algorithms.

Inspection of color codes on treads

The system TCC 8303.I marks the running surface which is output after the extruder, inspects the color lines for their completeness and measures the width of the running strip.

Benefits:

  • Integrated detection of the color code and width measurement of running strips
  • Detection of missing, wrong or incomplete lines
  • High quality marking due to controlling of horizontal position

Material parameters:

  • Material width to 550mm
  • Material thickness to 50mm
  • Material feed to 30m/min
Special features:
  • Accuracy width measurement 0.2mm
  • Position accuracy of the cartridges: 0.2mm

The integrated system TCC 8303.I has been developed for the inspection of color codes on running surfaces of tires. The cartridges for the marking are inserted in a holder. A pneumatic height adjustment and a servo controlled horizontal positioning ensure a straight line and optimal position of the code lines. The color code is immediately inspected by an image processing system.

Thickness measurement of calenders

For the production of reeled resistors or sheet goods in calenders the thickness measurement is a vital factor for controlling and monitoring the production process. By applying systems of the RTP series, the profile thickness can be measured in various accuracy classes, thickness ranges and material widths.

Benefits:

  • Permanent high product quality while reducing raw material use
  • Fast controlling during warm up or product change due to adaptive traversing speed and high-dynamically measurement
  • No consequential costs due to isotopes or X-rays
  • Wear-free measurements instead of half time of radiometric tests
  • Highest temperature stability due to in-situ calibration
  • Customer-specific adjustable interface

Material parameters:

  • Material width from 50 mm to 3,800 m
  • Material feed to 25 m/min
  • Permitted material surface temperature max.: 100°C

Products of the RTP family are designed as C- or O-frames which are equipped with application-specific sensor technology (thru-beam, triangulation or laser line triangulation).

Special features:
  • Linearity ±5µm
  • Measuring gap 15mm
  • Dimensional thickness measurement, independent from material components

The system RTP 8301.EO operates according to a combination principle consisting of a thru-beam sensor, an eddy current sensor and a measuring roller. The eddy current sensor and the thru-beam sensor are applied on an innovative measuring clamp. Since the sensor measures the distance from the clamp to the roller, the lower side of the material is detected. As the sensor performance is specially aligned with the measuring task a huge measuring gap is possible while offering highest precision. The thru-beam sensor detects the upper side of the material. The thickness of the target is the difference between the two signals. The measuring clamp is equipped with a pneumatically cleaning mechanism and therefore ideal for the application in harsh environment. The profilometer corresponds to the TIP 8301 regarding its functionality. However, it has a different operators´ frontend and evaluation functions.

Special features:
  • Linearity thickness ±5µm
  • Measuring gap 18mm
  • Dimensional thickness measurement, independent from material components

The RTP 8301.CT is based on laser triangulation sensors and therefore ensures the measurement being independently from material constants. The system is designed as O-frame, both sensors detect the thickness according to the differential method. In order to ensure highest precision, the laser beams of the sensors are accurately adjusted during the production process using optoelectronic tools which have been specially developed. The system is ideal for monitoring high-dynamically processes due to its high measuring rate. The O-frame mechanics of the system dispose of a compensation frame which does not vary with temperature and which is used in order to avoid temperature fluctuations of the measuring frame using further sensors. The profilometer corresponds to the TIP 8301.CT regarding its functionality. However, it has a different operators´ frontend and evaluation functions.

Special features:
  • Linearity from ±5µm
  • Measuring gap 20mm
  • Immersion depth from 50° to 1,000mm
  • Special sizes on request
  • Measuring rate to 20kHz

The RTP 8302.T is based on the laser triangulation sensors and therefore ensures the measurement being independently from material constants. In order to ensure highest precision, the laser beams of the sensors are accurately adjusted during the production process using optoelectronic tools which have been specially developed. The system is ideal for monitoring high-dynamically processes due to its high measuring rate. The C-frame mechanics of the system disposes of an automated in-situ calibration in order to avoid interferences caused by temperature.

Special features:
  • Linearity ±10µm, 40mm measuring range
  • Gap width 300mm
  • Immersion depth from 50° to 1,000mm
  • Special sizes on request
  • Measuring rate to 2kHz

The RTP 8302.LLT is based on the laser line triangulation sensors and therefore ensures the measurement being independently from surface characteristics of the target material. Combined to point sensors, the system offers more precision in the case of gap width. The C-frame mechanics of the system disposes of an automated in-situ calibration in order to avoid interferences caused by temperature.

Profile thickness measurement of roller head installations

For the production of reeled resistors or sheet goods on roller head installations the thickness measurement is an essential factor for controlling and monitoring the production process. Applying systems of the RTP series, the profile thickness can be measured in various accuracy classes, thickness ranges and material widths.

Benefits:

  • Permanent high product quality while reducing raw material use
  • Fast controlling during warm up or product change due to adaptive traversing speed and high-dynamically measurement
  • No consequential costs due to isotopes or X-rays
  • Wear-free measurements instead of half time of radiometric tests
  • Highest temperature stability due to in-situ calibration
  • Customer-specific adjustable interface

Material parameters:

  • Material width from 50 mm to 3,800m
  • Material feed to 25m/min
  • Permitted material surface temperature max.: 100°C

Products of the RTP family are designed as C- or O-frames which are equipped with application-specific sensor technology (thru-beam, triangulation or laser line triangulation).

Special features:
  • Linearity ±5µm
  • Measuring gap 15mm
  • Dimensional thickness measurement, independent from material components

The system RTP 8301.EO operates according to a combination principle consisting of a thru-beam sensor, an eddy current sensor and a measuring roller. The eddy current sensor and the thru-beam sensor are applied on an innovative measuring clamp. Since the sensor measures the distance from the clamp to the roller, the lower side of the material is detected. As the sensor performance is specially aligned with the measuring task a huge measuring gap is possible while offering highest precision. The thru-beam sensor detects the upper side of the material. The thickness of the target is the difference between the two signals. The measuring clamp is equipped with a pneumatically cleaning mechanism and therefore ideal for the application in harsh environment. The profilometer corresponds to the TIP 8301 regarding its functionality. However, it has a different operators´ frontend and evaluation functions.

Special features:
  • Linearity thickness ±5µm
  • Measuring gap 18mm
  • Dimensional thickness measurement, independent from material components

The RTP 8301.CT is based on laser triangulation sensors and therefore ensures the measurement being independently from material constants. The system is designed as O-frame, both sensors detect the thickness according to the differential method. In order to ensure highest precision, the laser beams of the sensors are accurately adjusted during the production process using optoelectronic tools which have been specially developed. The system is ideal for monitoring high-dynamically processes due to its high measuring rate. The O-frame mechanics of the system dispose of a compensation frame which does not vary with temperature and which is used in order to avoid temperature fluctuations of the measuring frame using further sensors. The profilometer corresponds to the TIP 8301.CT regarding its functionality. However, it has a different operators´ frontend and evaluation functions.

Special features:
  • Linearity from ±5µm
  • Measuring gap 20mm
  • Immersion depth from 50° to 1,000mm
  • Special sizes on request
  • Measuring rate to 20kHz

The RTP 8302.T is based on the laser triangulation sensors and therefore ensures the measurement being independently from material constants. In order to ensure highest precision, the laser beams of the sensors are accurately adjusted during the production process using optoelectronic tools which have been specially developed. The system is ideal for monitoring high-dynamically processes due to its high measuring rate. The C-frame mechanics of the system disposes of an automated in-situ calibration in order to avoid interferences caused by temperature.

Special features:
  • Linearity ±10µm, 40mm measuring range
  • Gap width 300mm
  • Immersion depth from 50° to 1,000mm
  • Special sizes on request
  • Measuring rate to 2kHz

The RTP 8302.LLT is based on the laser line triangulation sensors and therefore ensures the measurement being independently from surface characteristics of the target material. Combined to point sensors, the system offers more precision in the case of gap width. The C-frame mechanics of the system disposes of an automated in-situ calibration in order to avoid interferences caused by temperature.