X-ray quality control for cables intended for energy distribution

Energy transmission cables must deliver high performance and are manufactured through highly controlled production processes. Used in submarine and underground applications, they ensure the reliable transfer of energy to the points where it is needed. To guarantee safe and consistent electricity distribution, cable quality is an essential requirement. In this context, Sikora presents X-RAY 8000 Advanced, a benchmark system for quality control in CV lines, designed to support the production of energy cables with high standards of reliability, precision and safety.

Directly after the extruder in the production of CV pipes, the X-RAY 8000 Advanced X-ray measuring system measures the dimensions of the cable – such as wall thickness, eccentricity, diameter, and ovality. Unlike conventional systems on the market, the X-RAY 8000 Advanced features unique High-Speed Technology (HST). It is equipped with 16 measuring sensors, which reduces the measuring distances and thus measures at least 10 times faster than conventional systems. The result: the measuring values are available in less than 30 seconds for immediate centering and distortion-free control to the target dimension within 100 seconds.

Continuous use of the X-RAY 8000 Advanced enables a wall thickness reduction of around 5%, resulting in significant material and cost savings. The 5% material savings correspond to a CO2 reduction of around 375 tons per year – comparable to approximately 125 round-trip flights between Frankfurt and New York. The X-RAY 8000 Advanced thus contributes to greater sustainability in cable production.

The durable XLL X-ray technology ensures a long service life. Special, self-cleaning, and non-toxic (NTX) measuring windows guarantee particularly safe and healthy handling in the CV line. In addition to the measuring system, a control cabinet containing an industrial PC for evaluating the X-ray image is supplied. All measuring values are clearly visualized and logged in real time on a TFT monitor.

The X-RAY 8000 Advanced can be integrated both vertically in CCV lines and VCV lines as well as in a horizontal line for medium-voltage cables. It can also be used in hybrid CV lines where both XLPE and PP are used as insulation materials.

For final quality control at the end of the CV line, the X-RAY 8700 NXT records the cold values of the cable. In combination with the X-RAY 8000 Advanced at the beginning of the line, the shrinkage values for all three insulation layers of the cable can also be precisely determined. This ensures optimal process control and meets existing cable quality requirements for maximum reliability and safety.