EXTRUSION CONTROL

NEXiS® CS3G Series Extrusion Controller

NEXiS®  CS3G Series - front view
NEXiS®  CS3G Series - connector panel view

Features

 

  • Provide PI control of insulation thickness on wire and cable insulation extrusion lines.
  • Controls insulation extruders or capstan drives.
  • May be used in other diameter-controlled extrusion processes.
  • Integrates seamlessly with Proton Products InteliSENS® SL and SLR Series Speed and Length Gauges for line speed measurement.
  • Integrates seamlessly with one or two Proton Products InteliSENS® DG series diameter gauges for insulation diameter measurement.
  • Single DG gauge variant for diameter control (D variant) from either hot or cold measured diameter.
  • Double DG gauge variants available for automatic shrinkage compensation (HC – Hot-Cold variant) or Wall Thickness (WT variant) control.
  • Independent setting of tolerances, shrinkage, alarm functions and speed input.
  • Large back-lit dot-matrix LCD display.
  • Password protection of setting and product recipe presets for fast configuration.
  • Graphical FFT (Fast Fourier Transform) for analysis of periodic diameter variations.
  • Graphical statistical analysis and SPC (Statistical Process Control) to minimize material consumption.
  • SSFD (Single Scan Flaw Detection) for detection of insulation lump and neck flaws.
  • Housed in a rack-mountable enclosure (optional stand-alone mounting case is available).

Additional Information:

Series Brochure
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Dimensional drawings
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Pre-sales enquiry click here >

Manual request click here >

Support request click here >

NEXiS® CS3G Series Extrusion Controller

Introduction

The Proton Products NEXiS® CS3G Series of controllers are for use on wire insulation or other extrusion production lines.

NEXiS® CS3G Series controllers connect to Proton Products diameter gauges and speed and length gauges for measurement of insulation diameter and line speed respectively. These measurements are then fed into a PI feedback controller whose fully-isolated and floating output may be used to drive insulation extruders or capstan drives.

Insulation diameter is thus actively controlled and kept in tolerance by the NEXiS® CS3G controller.

NEXiS® CS3G Series controllers also have advanced features such as a large back-lit dot-matrix LCD display, password protection, product recipe presets, graphical FFT, graphical SPC, statistical analysis and Single Scan Flaw Detection (SSFD, for detection of insulation lump and neck flaws).

CS-Operating-Principle

Variants

Variants
Control algorithm
NEXiS® CS3G-DDiameter control
NEXiS® CS3G-HCHot-Cold automatic shrinkage compensation control
NEXiS® CS3G-WTWall thickness control

Insulation Diameter Control

Using the Cold diameter only (single DG gauge – D variant)

CS3G-image-01

The NEXiS® CS3G is connected to the Cold DG diameter gauge after the water cooling trough. The Cold diameter measurement is used to control the extruder so that the final insulation diameter is held within tolerance. Since the Cold diameter measurement is located far from the extruder, this control system response time is relatively slow (and dependent on the line speed), but no shrinkage offset is required.

Using the Hot diameter and a user-set shrinkage offset (single DG gauge – D variant)

CS3G-image-02

The NEXiS® CS3G is connected to the Hot DG diameter gauge before the water cooling trough. A shrinkage offset due to cooling is set by the operator and used in conjunction with the Hot diameter measurement to control the extruder so that the final insulation diameter is held within tolerance. Since the Hot diameter measurement is located close to the extruder, this control system response time is relatively fast.

Using both Hot and Cold diameters and an automatically-calculated shrinkage offset (two DG gauge – HC variant)

CS3G-image-03

The NEXiS® CS3G is connected to the Hot and Cold DG diameter gauges before and after the water cooling trough respectively. The shrinkage offset due to cooling is automatically calculated from the Hot and Cold diameter measurements and used in conjunction with the Hot diameter to control the extruder so that the final insulation diameter is held within tolerance. Since the Hot diameter measurement is located close to the extruder, this control system response time is relatively fast and the user does not need to figure out a shrinkage offset.

Wall Thickness Control

Using core and Hot diameters and a user-set shrinkage offset (two DG gauge – WT variant)

CS3G-image-04

The NEXiS® CS3G is connected to the Core DG gauge and Hot DG diameter gauge before the water cooling trough. A shrinkage offset due to cooling is set by the operator and used in conjunction with the Hot and Core diameter measurements to control the extruder so that the final insulation wall thickness is held within tolerance. Since the Hot diameter measurement is located close to the extruder, this control system response time is relatively fast.

Specifications

ScreenBlack and white 320×240 pixel graphical display - 120mm (4.72”) × 85mm (3.35”)
Serial communicationsRS232USBCANbus - (for connection to up to 2× DG Series gauges)
Line speed inputsAnalogueTwo inputs available for 0 to 10V and 0 to 50V analogue line speed signals; end-user configurable scaling
PulseTwo inputs available for 0 to 3V and 0 to 10V pulsed line speed signals; maximum frequency 250 kHz; end-user configurable scaling
4×Relay contact outputsFunction (end-user configurable)Gauge OKSSFD lump or neck flaw detectedX or Y upper tolerance exceededX or Y lower tolerance exceeded
X upper tolerance exceededX lower tolerance exceededY upper tolerance exceededY lower tolerance exceeded
ElectricalMaximum voltage50VDC / 30VAC
Maximum current500mA
On resistance (@ 100mA)< 0.1Ω
Off resistance> 10 MΩ
Analogue output 1Function (end-user configurable)ØXØXY
ElectricalOutput voltage range0V to +10V
Maximum output current2mA
Resolution16-bit
Output voltage scaling is end-user configurable
Analogue output 2Function (end-user configurable)ØYAverage Error
ElectricalOutput voltage rangeØY: 0V to +10V
Average Error: -10V to +10V
Maximum output current2mA
Resolution16-bit
Output voltage scaling is end-user configurable
Control algorithmAdvanced Control Algorithm (ACA)
SPCGraphical histogramCpCpk
SPC controlStatistical Process Control: minimize insulation material consumption whilst maintaining in tolerance insulation diameter
FFTFast Fourier Transform: displays amplitude versus frequency of periodic diameter variations
SSFDSingle Scan Flaw Detection: detection of lump and neck flaws
PresetsNominal diameter+Tolerance-Tolerance+Flaw (Lump)-Flaw (Neck)
Product recipes50 sets of product presets may be stored in memory for rapid recall
StatisticsMean diameterStandard deviation (sigma)Maximum diameterMinimum diameter
Specification
Minimum
Typical
Maximum
Units
Weight2.5kg
5.5lb
Length230mm
9.1inch
Width213.1mm
8.4inch
Height128.5mm
5.1inch
Power supply voltage (rms)85264VAC
Power supply frequency4765440Hz
Power supply current (rms)2.5A
Power consumption110W
Ambient temperature545°C
41113°F
Relative humidity @ 38°C / 105°F90%
Ingress Protection (IP) ratingIP50-
PI Controller output voltage-1010V
PI Controller output current10mA
PI Controller output resistance10Ω
PI Controller resolution12bit