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Reduce Material Costs in Automotive Wire Production

The color recognition system can be integrated into a new or existing production line. It can also be used as a stand-alone unit.

DVS SK-400-C sensitive color
recognition system.

Imagine – You are producing an ultra-thin cable with 0.13 mm² at a production speed of 1800 m/min. Now you get the task to monitor the insulation color just by looking at it. Do you think you could detect color variations in – let’s say – 200 m of cable on the running line? An impossible task! This is where Rosendahl sees cost-saving potentials by using an extremely sensitive color recognition system, called DVS SK-400-C. Rosendahl developed this innovative sensor system to detect even the slightest deviations.

The color recognition sensor system measures the main and stripe colors, as well as the stripe width, according to previously set references. It is also possible to optimize the product recipe. Due its sensitivity, especially the master-batch demand can be decisively reduced. Rosendahl has subjected it to intensive tests on their RA-A automotive wire production line. The results reveal that recipes with 2.5% master-batch can easily be decreased down to 1.5%, while still maintaining the same color shade. All these improvements lead to immediate savings regarding the master-batch, and thus on material costs.

The DVS SK-400C-C’s main component is a PC-based evaluation unit with 360° camera surveillance. This unit consists of four cameras which are covered by a protective housing. This enables continuous color quality monitoring, which is also displayed on the reel protocol. Color reliability is therefore immediately assured, which makes color complaints and faulty productions a thing of the past. That means that waste and scrap are significantly reduced at start-up, during production and even during color changes.

Wire & Cable India